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Service data
2-3
2-3
Item Standard Service limit
Cylinder/Piston
Cylinder I.D
Taper
Out-of- round
Warpage
80.000 – 80.015 (3.1496 – 3.1502)
–
–
–
80.045 (3.1514)
0.05 (0.002)
0.05 (0.002)
0.05 (0.002)
Piston O.D.
Measurement point
Pin bore I.D.
79.970 – 79.980 (3.1484 – 3.1488)
3.5 (0.138) from bottom of skirt
16.002 – 16.008 (0.6300 – 0.6302)
79.955 (3.1478)
–
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
Second
Oil (side rail)
0.15 – 0.25 (0.006 - 0.009843)
0.30 – 0.45 (0.0118 - 0.01772)
0.20 – 0.70 (0.008 – 0.028)
0.39 (0.0154)
0.60 (0.0236)
0.90 (0.0354)
Ring-to-groove clearance
Top
Second
0.065 – 0.100 (0.0026 – 0.0039)
0.015 – 0.050 (0.006 – 0.0020)
0.115 (0.0045)
0.065 (0.0026)
Cylinder-to-piston clearance 0.030 – 0.055 (0.0012 – 0.0018) 0.18 (0.007)
Piston-to-piston pin clearance 0.002 – 0.014 (0.0001 – 0.0006) 0.04 (0.002)
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.
Pinion gear I.D.
Idle gear I.D.
Countershaft O.D. at kickstarter idle gear
16.466 – 16.484 (0.6483 – 0.6490)
16.516 – 16.534 (0.6502 – 0.6509)
17.016 – 17.034 (0.6699 – 0.6706)
16.983 – 16.994 (0.6686 – 0.6691)
16.46 (0.648)
16.55 (0.652)
17.06 (0.672)
16.97 (0.668)
Unit: mm (in) Unit: mm (in)
Item Standard Service limit
Crankshaft/Transmission
Crankshaft runout Right
Left
–
–
0.03 (0.001)
0.05 (0.002)
Connecting rod big end
Side clearance
Radial clearance
0.30 – 0.75 (0.012 – 0.030)
0.06 – 0.18 (0.002 – 0.007)
0.8 (0.03)
0.05 (0.002)
Transmission gear I.D. M4
M5
C1
C2
C3
23.020 – 23.041 (0.9063 – 0.9071)
23.020 – 23.041 (0.9063 – 0.9071)
20.020 – 20.041 (0.7882 – 0.7890)
25.020 – 25.041 (0.9850 – 0.9859)
25.020 – 25.041 (0.9850 – 0.9859)
23.07 (0.908)
23.07 (0.908)
20.06 (0.790)
25.06 (0.987)
25.06 (0.987)
Gear bushing D.I. M5
C1
C2
C3
20.000 – 20.021 (0.7866 – 0.7882)
17.000 – 17.018 (0.6693 – 0.6700)
22.000 – 22.021 (0.8661 – 0.8670)
22.000 – 22.021 (0.8661 – 0.8670)
20.05 (0.789)
17.04 (0.671)
22.04 (0.868)
22.04 (0.868)
O.D. M4
M5
C1
C2
C3
22.979 – 23.000 (0.9047 – 0.9055)
22.979 – 23.000 (0.9047 – 0.9055)
19.979 – 20.000 (0.7866 – 0.7874)
24.979 – 25.000 (0.9834 – 0.9843)
24.979 – 25.000 (0.9834 – 0.9843)
22.96 (0.904)
22.96 (0.904)
19.95 (0.785)
24.95 (0.982)
24.95 (0.982)
Countershaft O.D.
at C1 bushing
at C2/C3 bushing
at kickstarter idle gear
16.983 – 16.994 (0.6686 – 0.6691)
21.959 – 21.980 (0.8645 – 0.8654)
16.983 – 16.994 (0.6686 – 0.6691)
16.97 (0.668)
21.94 (0.864)
16.97 (0.668)
Shift fork I.D. C
R, L
11.003 – 11.024 (0.4332 – 0.4330)
12.035 – 12.056 (0.4738 – 0.4746)
11.04 (0.435)
12.07 (0.475)
Shift fork claw thickness C
R, L
4.93 – 5.00 (0.194 – 0.197)
4.93 – 5.00 (0.194 – 0.197)
4.8 (0.19)
4.8 (0.19)
Shift fork shaft O.D. C
R, L
10.983 – 10.994 (0.4324 – 0.4328)
11.966 – 11.984 (0.4711 – 0.4718)
10.97 (0.432)
11.95 (0.470)
Oil pump
Tip clearance
Body clearance
Side clearance
–
0.15 – 0.20 (0.006 – 0.008)
0.05 – 0.12 (0.002 – 0.004)
0.20 (0.008)
–
–
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