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Service Data
2-3
2-3
Item Standard Service limit
Cylinder/Piston
Cylinder I.D 78.000 – 78.015 (3.0709 - 3.0715) 78.04 (3.0724)
Taper – 0.05 (0.002)
Out-of- round – 0.05 (0.002)
Warpage – 0.05 (0.002)
Piston O.D. 77.970 – 77.980 (3.0696 - 3.07008) 77.89 (3.0665)
Measurement point
5.0 (0.2) from bottom of skirt
–
Pin bore I.D. 16.002 – 16.008 (0.6300 – 0.6302) 16.03 (0.631)
Piston pin O.D. 15.994 – 16.000 (0.6297 – 0.6299) 15.98 (0.629)
Piston ring
End gap
Top 0.15 – 0.25 (0.008 - 0.0098425) 0.39 (0.01535)
Second 0.30 – 0.45 (0.012 - 0.0018) 0.59 (0.02323)
Oil (side rail) 0.20 – 0.70 (0.008 – 0.028) 0.90 (0.035)
Ring-to-groove clearance
Top 0.065 – 0.100 (0.0026 – 0.0039) 0.115 (0.0045)
Second 0.015 – 0.050 (0.0006 – 0.0020) 0.065 (0.0026)
Cylinder-to-piston clearance 0.020 – 0.045 (0.0008 – 0.0018) 0.18 (0.007)
Piston-to-piston pin clearance 0.002 – 0.014 (0.0001 – 0.0006) 0.04 (0.002)
Connecting rod small end I.D. 16.016 – 16.034 (0.6305 – 0.6313) 16.04 (0.631)
Clutch/Gearshift Linkage
Recommended clutch fluid DOT 4 brake fluid –
Clutch spring free length 27.6 (1.09) 26.8 (1.06)
Clutch disc thickness 3.22 – 3.38 (0.127 – 0.133) 3.15 (0.124)
Clutch plate warpage – 0.10 (0.004)
Clutch slave cylinder I.D. 27.000 – 27.021 (1.0630 – 1.0638) –
Clutch slave piston O.D. 26.940 – 26.960 (1.0606 – 1.0614) –
Kickstarter
Spindle O.D. 16.466 – 16.484 (0.6483 – 0.6490) 16.46 (0.648)
Pinion gear I.D. 16.516 – 16.534 (0.6502 – 0.6509) 16.55 (0.652)
Idle gear I.D. 17.016 – 17.034 (0.6699 – 0.6706) 17.06 (0.672)
Countershaft O.D.
at kickstarter idle gear 16.983 – 16.994 (0.6686 – 0.6691) 16.97 (0.668)
Item Standard Service limit
Crankshaft/Transmission
Crankshaft runout Right – 0.03 (0.001)
Left – 0.05 (0.002)
Connecting rod big end
Side clearance 0.30 – 0.75 (0.012 – 0.030) 0.8 (0.03)
Radial clearance 0.06 – 0.18 (0.002 – 0.007) 0.05 (0.002)
Transmission gear I.D. M4 23.020 – 23.041 (0.9063 – 0.9071) 23.07 (0.908)
M5 23.020 – 23.041 (0.9063 – 0.9071) 23.07 (0.908)
C1 20.020 – 20.041 (0.7882 – 0.7890) 20.06 (0.790)
C2 25.020 – 25.041 (0.9850 – 0.9859) 25.06 (0.987)
C3 25.020 – 2.041 (0.9850 – 0.9859) 25.06 (0.987)
Gear bushing D.I. M5 20.000 – 20.021 (0.7866 – 0.7882) 20.05 (0.789)
C1 17.000 – 17.018 (0.6693 – 0.6700) 17.04 (0.671)
C2 22.000 – 22.021 (0.8661 – 0.8670) 22.04 (0.868)
C3 22.000 – 22.021 (0.8661 – 0.8670) 22.04 (0.868)
O.D. M4 22.979 – 23.000 (0.9047 – 0.9055) 22.96 (0.904)
M5 22.979 – 23.000 (0.9047 – 0.9055) 22.96 (0.904)
C1 19.979 – 20.000 (0.7866 – 0.7874) 19.95 (0.785)
C2 24.979 – 25.000 (0.9834 – 0.9843) 24.95 (0.982)
C3 24.979 – 25.000 (0.9834 – 0.9843) 24.95 (0.982)
Countershaft O.D.
at C1 bushing 16.983 – 16.994 (0.6686 – 0.6691) 16.97 (0.668)
at C2/C3 bushing 21.959 – 21.980 (0.8645 – 0.8654) 21.94 (0.864)
at kickstarter idle gear 16.983 – 16.994 (0.6686 – 0.6691) 16.97 (0.668)
Shift fork I.D. C 11.003 – 11.024 (0.4332 – 0.4330) 11.04 (0.435)
R, L 12.035 – 12.056 (0.4738 – 0.4746) 12.07 (0.475)
Shift fork claw thickness C 4.93 – 5.00 (0.194 – 0.197) 4.8 (0.19)
R, L 4.93 – 5.00 (0.194 – 0.197) 4.8 (0.19)
Shift fork shaft O.D. C 10.983 – 10.994 (0.4324 – 0.4328) 10.97 (0.432)
R, L 11.966 – 11.984 (0.4711 – 0.4718) 11.95 (0.470)
Oil pump
Tip clearance – 0.20 (0.008)
Body clearance 0.15 – 0.20 (0.006 – 0.008) –
Side clearance 0.05 – 0.12 (0.002 – 0.004) –
Unit: mm (in) Unit: mm (in)
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