CYLINDER HEAD/VALVES SPECIFICATIONS

Unit: mm (in)

ITEM

STANDARD

SERVICE LIMIT

Cylinder compression

402 kPa (4.1 kgf/cmJ, 58 psi) at 360 rpm

Cylinder head warpage

0.05 (0.002)

Decompressor clearance

’05-’07

Ex valve clearance + 0.35 mm (0.014)

Valve and

Valve clearance

IN

0.16 ±0.03 (0.006 ±0.001)

valve guide

EX

0.28 ± 0.03 (0.011 ±0.001)

Valve stem O. D.

IN

5.475-5.490 (0.2156-0.2161)

EX

4.965 — 4.980 (0.1955 — 0.1961)

4.96 (0.195)

Valve guide I. D.

IN

5.500 — 5.512 (0.2165 — 0.2170)

5.552 (0.2186)

EX

5.000 — 5.012 (0.1969 — 0.1973)

5.052 (0.1989)

Stem-to-guide clear­

IN

0.010 — 0.037 (0.0004 — 0.0015)

ance

EX

0.020 — 0.047 (0.0008 — 0.0019)

Valve guide projec­

IN

16.1 -16.3(0.63 — 0.64)

tion above cylinder head

EX

17.9-18.1 (0.70-0.71)

Valve seat width

IN

1.1 -1.3(0.04-0.05)

2.0 (0.08)

EX

1.3-1.5(0.05-0.06)

2.0 (0.08)

Valve spring free length

IN

40.68 (1.602)

39.7 (1.56)

EX

42.82 (1.686)

41.9 (1.65)

Rocker arm

Rocker arm I. D.

12.000 — 12.018 (0.4724 — 0.4731)

12.05 (0.474)

Rocker arm shaft O. D.

11.967 — 11.975 (0.4711 — 0.4715)

11.92 (0.469)

Rocker arm-to-shaft clearance

0.025 — 0.051 (0.0010 — 0.0020)

0.10 (0.004)

Camshaft

Cam lobe height

IN

36.890 — 37.130 (1.4524 — 1.4618)

36.890 (1.4524)

EX

35.063 — 35.303 (1.3804 — 1.3899)

35.063 (1.3804)

Valve lifter O. D.

25.978 — 25.993 (1.0228 — 1.0233)

25.97 (1.022)

Valve lifter bore I. D.

26.010 — 26.026 (1.0240 — 1.0246)

26.04 (1.025)

CYLINDER/PISTON SPECIFICATIONS

Unit: mm (in)

ITEM

STANDARD

SERVICE LIMIT

Cylinder

I. D.

96.000 — 96.015 (3.7795 — 3.7801)

96.025 (3.7805)

Out of round

0.010 (0.0004)

Taper

0.010 (0.0004)

Warpage

0.05 (0.002)

Piston, piston ring

Piston mark direction

"IN" mark facing toward the intake side

Piston O. D.

95.970 — 95.980 (3.7783 — 3.7787)

95.94 (3.777)

Piston O. D. measurement point

5.0 mm (0.20 in) from the bottom of skirt

Piston pin bore I. D.

19.002 — 19.008 (0.7481 -0.7483)

19.03 (0.749)

Piston pin O. D.

18.994 — 19.000 (0.7478 — 0.7480)

18.98 (0.747)

Piston-to-piston pin clearance

0.002 — 0.014 (0.0001 — 0.0006)

0.04 (0.002)

Top ring mark

"R" mark side facing up

Piston ring-to-ring groove clearance

Top

0.065 — 0.100 (0.0026 — 0.0039)

0.115 (0.0045)

Piston ring end gap

Top ring

0.25-0.31 (0.010-0.012)

0.45 (0.018)

Oil ring (side rail)

0.20-0.70 (0.008-0.028)

0.90 (0.035)

Cylinder-to-piston clearance

0.020 — 0.045 (0.0008 — 0.0018)

0.085 (0.0033)

Connecting rod small end I. D.

’05 — ’07

19.016 — 19.034 (0.7487 — 0.7494)

19.04 (0.750)

After ’07

19.016 — 19.038 (0.7487 — 0.7495)

19.04 (0.750)

Connecting rod-to-piston pin clearance

’05 — ’07

0.016 — 0.040 (0.0006 — 0.0016)

0.06 (0.002)

After ’07

0.016 — 0.044 (0.0006 — 0.0017)

0.06 (0.002)

CLUTCH/STARTER CLUTCH/KICKSTARTER/GEARSHIFT LINKAGE SPECIFICATIONS

Unit: mm (in)

ITEM

STANDARD

SERVICE LIMIT

Clutch lever freeplay

10-20 (3/8-13/16)

Clutch spring free length

44.7 (1.76)

43.7 (1.72)

Clutch disc thickness

2.92-3.08 (0.115-0.121)

2.85 (0.112)

Clutch plate warpage

0.15 (0.006)

Kickstarter pinion gear I. D.

22.007 — 22.028 (0.8664 — 0.8672)

22.05 (0.868)

Kickstarter pinion gear bushing

I. D.

20.000 — 20.021 (0.7874 — 0.7882)

20.04 (0.789)

O. D.

21.979 — 22.000 (0.8653 — 0.8661)

21.96 (0.865)

Kickstarter spindle O. D.

19.980 — 19.993 (0.7866 — 0.7871)

19.97 (0.786)

Kickstarter idle gear I. D.

20.020-20.041 (0.7882-0.7890)

20.07 (0.790)

Kickstarter idle gear bushing

I. D.

17.000 — 17.018 (0.6693 — 0.6700)

17.04 (0.671)

O. D.

19.979 — 20.000 (0.7866 — 0.7874)

19.96 (0.786)

Countershaft O. D. at kickstarter idle gea

16.966 — 16.984 (0.6680 — 0.6687)

16.95(0.667)

Starter driven gear boss

I. D.

36.009 — 36.034 (1.4177 — 1.4187)

36.034(1.4187)

O. D.

45.660 — 45.673 (1.7976 — 1.7981)

45.660 (1.7976)

Reduction gear A I. D.

12.010 — 12.050 (0.4728 — 0.4744)

12.050 (0.4744)

Reduction gear В I. D.

10.045 — 10.085 (0.3955 — 0.3970)

10.085 (0.3970)

Idle gear I. D.

12.010 — 12.050 (0.4728 — 0.4744)

12.050(0.4744)

Gear holder shafts O. D.

11.989 — 12.000 (0.4720 — 0.4724)

11.989 (0.4720)

Reduction gear shaft O. D.

9.980 — 9.995 (0.3929 — 0.3935)

9.980 (0.3929)

CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER SPECIFICATIONS (’05 — ’07)

Unit: mm (in

ITEM

STANDARD

SERVICE LIMIT

Crankshaft

Side clearance

0.30-0.75 (0.012-0.030)

0.75 (0.030)

Radial clearance

0.006 — 0.018 (0.0002 — 0.0007)

0.05 (0.002)

Runout

R

0.03 (0.001)

L

0.05 (0.002)

Transmission

Gear I. D.

M4

28.007 — 28.028 (1.1026 — 1.1035)

28.05 (1.104)

M5

25.020 — 25.041 (0.9850 — 0.9859)

25.07 (0.987)

Cl

22.007 — 22.028 (0.8664 — 0.8672)

22.04 (0.868)

C2

30.020-30.041 (1.1819-1.1827)

30.07 (1.184)

C3

25.020 — 25.041 (0.9850 — 0.9859)

25.07 (0.987)

Bushing O. D.

M4

27.959-27.980 (1.1007- 1.1016)

27.94(1.100)

C2

29.979 — 30.000 (1.1803 — 1.1811)

29.95 (1.179)

Bushing I. D.

C2

27.000 — 27.021 (1.0630 — 1.0638)

27.04(1.065)

Gear-to-bushing

M4

0.027 — 0.069 (0.0011 — 0.0027)

0.11 (0.004)

clearance

C2

0.020 — 0.062 (0.0008 — 0.0024)

0.12 (0.005)

Mainshaft O. D.

M5

24.959 — 24.980 (0.9826 — 0.9835)

24.94 (0.982)

Countershaft O. D.

C1 bearing

18.987 — 19.000 (0.7475 — 0.7480)

18.94 (0.746)

C2 bushing

26.959 — 26.980 (1.0614 — 1.0622)

26.94 (1.061)

C3

24.959 — 24.980 (0.9826 — 0.9835)

24.96 (0.983)

Gear-to-shaft

M5

0.040 — 0.082 (0.0016 — 0.0032)

0.13 (0.005)

clearance

C3

0.040 — 0.082 (0.0016 — 0.0032)

0.082 (0.0032)

Bushing-to-shaft

clearance

C2

0.020 — 0.062 (0.0008 — 0.0024)

0.12 (0.005)

Shiftfork, shift

Fork claw thickness

4.93-5.00 (0.194-0.197)

4.8 (0.19)

fork shaft

Shift fork I. D.

С

10.989 — 11.011 (0.4326 — 0.4335)

11.011 (0.4335)

R, L

12.035 — 12.056 (0.4738 — 0.4746)

12.070 (0.4752)

Fork shaft O. D.

С

10.969 — 10.980 (0.4319 — 0.4323)

10.969 (0.4318)

R, L

11.966 — 11.984 (0.4711 — 0.4718)

11.950 (0.4705)

CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER SPECIFICATIONS (After ’07)

Unit: mm (in)

ITEM

STANDARD

SERVICE LIMIT

Crankshaft

Side clearance

0.30-0.75 (0.012-0.030)

0.75 (0.030)

Radial clearance

0.006 — 0.018 (0.0002 — 0.0007)

0.05 (0.002)

Runout

R

0.03(0.001)

L

0.05 (0.002)

Transmission

Gear I. D.

M4

28.007 — 28.028 (1.1026 — 1.1035)

28.05 (1.104)

M5

28.020 — 28.033 (1.1031 — 1.1037)

28.07 (1.105)

Cl

22.007 — 22.028 (0.8664 — 0.8672)

22.04 (0.868)

C2

30.020-30.041 (1.1819-1.1827)

30.07 (1.184)

C3

28.020 — 28.041 (1.1031 — 1.1040)

28.07 (1.105)

Bushing O. D.

M4

27.959 — 27.980 (1.1007 — 1.1016)

27.94(1.100)

M5

27.959-27.980 (1.1007-1.1016)

27.94 (1.100)

C2

29.979 — 30.000 (1.1803 — 1.1811)

29.95 (1.179)

C3

27.979 — 28.000 (1.1015 — 1.1024)

27.95 (1.100)

Bushing I. D.

M5

25.000 — 25.021 (0.9843 — 0.9851)

25.04 (0.9858)

C2

27.000 — 27.021 (1.0630 — 1.0638)

27.04 (1.065)

C3

25.000-25.021 (0.9843-0.9851)

25.04 (0.9858)

Gear-to-bushing

M4

0.027 — 0.069 (0.0011 — 0.0027)

0.11 (0.004)

clearance

M5

0.040 — 0.074 (0.0016 — 0.0029)

0.12 (0.005)

C3

0.020 — 0.062 (0.0008 — 0.0024)

0.12(0.005)

C2

0.020 — 0.062 (0.0008 — 0.0024)

0.12 (0.005)

Mainshaft O. D.

M5

24.959 — 24.980 (0.9826 — 0.9835)

24.94 (0.982)

Countershaft O. D.

Cl bearing

18.987 — 19.000 (0.7475 — 0.7480)

18.94 (0.746)

C2 bushing

26.959 — 26.980 (1.0614 — 1.0622)

26.94(1.061)

C3 bushing

24.959 — 24.980 (0.9826 — 0.9835)

24.96 (0.983)

Bushing-to-shaft

clearance

M5, C2, C3

0.020 — 0.062 (0.0008 — 0.0024)

0.12(0.005)

Shift fork, shift

Fork claw thickness

4.93-5.00 (0.194-0.197)

4.8 (0.19)

fork shaft

Shift fork I. D.

С

10.989-11.011 (0.4326-0.4335)

11.011 (0.4335)

R, L

12.035 — 12.056 (0.4738 — 0.4746)

12.070 (0.4752)

Fork shaft O. D.

С

10.969 — 10.980 (0.4319 — 0.4323)

10.969 (0.4318)

R, L

11.966 — 11.984 (0.4711 — 0.4718)

11.950 (0.4705)

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