Page 32 of 457
2-4
ENGINE SPECIFICATIONSSPEC
ItemStandardLimit
Camshafts
Drive system
Camshaft cap inside diameter
Camshaft journal diameter
Camshaft-journal-to-camshaft-
cap clearance
Intake camshaft lobe dimensions
Measurement A
Measurement B
Exhaust camshaft lobe dimensions
Measurement A
Measurement B
Max. camshaft runout
Chain drive (right)
22.500 22.521 mm (0.8858 0.8867 in)
22.459 22.472 mm (0.8842 0.8847 in)
0.028 0.062 mm (0.0011 0.0024 in)
32.85 32.95 mm (1.293 1.297 in)
25.14 25.24 mm (0.990 0.994 in)
30.75 30.85 mm (1.211 1.215 in)
23.09 23.19 mm (0.909 0.913 in)
32.75 mm
(1.289 in)
25.04 mm
(0.986 in)
30.65 mm
(1.207 in)
22.99 mm
(0.905 in)
0.03 mm
(0.0012 in)
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Page 33 of 457
2-5
ENGINE SPECIFICATIONSSPEC
Head Diameter Face Width Seat Width Margin Thickness
ItemStandardLimit
Timing chain
Model / number of links
Tensioning system
RH2020 / 122
Automatic
Valves, valve seats, valve guides
Valve clearance (cold)
Intake
Exhaust
Valve dimensions
0.11 0.20 mm (0.0043 0.0079 in)
0.21 0.25 mm (0.0083 0.0098 in)
Valve head diameter A
Intake
Exhaust
Valve face width B
Intake
Exhaust
Valve seat width C
Intake
Exhaust
Valve margin thickness D
Intake
Exhaust
Valve stem diameter
Intake
Exhaust
Valve guide inside diameter
Intake
Exhaust
Valve-stem-to-valve-guide clearance
Intake
Exhaust
Valve stem runout
Valve seat width
Intake
Exhaust
23.4 23.6 mm (0.9213 0.9291 in)
24.9 25.1 mm (0.9803 0.9882 in)
1.76 2.90 mm (0.0693 0.1142 in)
1.76 2.90 mm (0.0693 0.1142 in)
0.9 1.1 mm (0.0354 0.0433 in)
0.9 1.1 mm (0.0354 0.0433 in)
0.5 0.9 mm (0.0197 0.0354 in)
0.5 0.9 mm (0.0197 0.0354 in)
3.975 3.990 mm (0.1565 0.1571 in)
4.460 4.475 mm (0.1756 0.1762 in)
4.000 4.012 mm (0.1575 0.1580 in)
4.500 4.512 mm (0.1772 0.1776 in)
0.010 0.037 mm (0.0004 0.0015 in)
0.025 0.052 mm (0.0010 0.0020 in)
0.9 1.1 mm (0.0354 0.0433 in)
0.9 1.1 mm (0.0354 0.0433 in)
1.6 mm (0.06 in)
1.6 mm (0.06 in)
0.5 mm (0.02 in)
0.5 mm (0.02 in)
3.945 mm
(0.1553 in)
4.425 mm
(0.1742 in)
4.050 mm
(0.1594 in)
4.550 mm
(0.1791 in)
0.08 mm
(0.0032 in)
0.10 mm
(0.0039 in)
0.01 mm
(0.0004 in)
1.6 mm (0.06 in)
1.6 mm (0.06 in)
ProCarManuals.com
Page 34 of 457
2-6
ENGINE SPECIFICATIONSSPEC
ItemStandardLimit
Valve springs
Free length
Intake
Exhaust
Installed length (valve closed)
Intake
Exhaust
Compressed spring force
(installed)
Intake
Exhaust
Spring tilt
Intake
Exhaust
Winding direction (top view)
Intake
Exhaust
39.3 mm (1.55 in)
39.3 mm (1.55 in)
32.7 mm (1.29 in)
32.8 mm (1.29 in)
145.9 167.9 N (14.88 17.12 kg,
32.80 37.74 lb)
164.1 188.9 N (16.73 19.26 kg,
36.89 42.46 lb)
Clockwise
Clockwise37.3 mm (1.47 in)
37.3 mm (1.47 in)
2.5/ 1.7 mm
(0.07 in)
2.5/ 1.7 mm
(0.07 in)
Cylinders
Cylinder arrangement
Bore stroke
Compression ratio
Bore
Max. out-of-round
Forward-inclined, parallel 4-cylinder
77.0 mm 53.6 mm (3.03 2.11 in)
12.4 : 1
77.00 77.01 mm (3.0315 3.0319 in)
0.005 mm
(0.0002 in)
ProCarManuals.com
Page 35 of 457
2-7
ENGINE SPECIFICATIONSSPEC
ItemStandardLimit
Piston
Piston-to-cylinder clearance
Diameter D
Height H
Piston pin bore (in the piston)
Diameter
Offset
Offset direction
Piston pins
Outside diameter
Piston-pin-to-piston-pin-bore
clearance
Piston rings
Top ring
Ring type
Dimensions (B T)
End gap (installed)
Ring side clearance
2nd ring
Ring type
Dimensions (B T)
End gap (installed)
Ring side clearance
Oil ring
Dimensions (B T)
End gap (installed)
0.010 0.035 mm (0.0004 0.0014 in)
76.975 76.990 mm (3.0305 3.0311 in)
5 mm (0.20 in)
17.002 17.013 mm
(0.6694 0.6698 in)
0.5 mm (0.0197 in)
Intake side
16.991 17.000 mm
(0.6689 0.6693 in)
0.002 0.022 mm (0.0001 0.0009 in)
Barrel
0.90 2.75 mm (0.04 0.11 in)
0.15 0.25 mm (0.0059 0.0098 in)
0.030 0.065 mm (0.0012 0.0026 in)
Taper
0.80 2.75 mm (0.03 0.11 in)
0.30 0.45 mm (0.0118 0.0177 in)
0.020 0.055 mm (0.0008 0.0022 in)
1.50 2.25 mm (0.06 0.09 in)
0.10 0.40 mm (0.0039 0.0158 in)0.120 mm
(0.0047 in)
17.043 mm
(0.6710 in)
16.971 mm
(0.6682 in)
0.072 mm
(0.0028 in)
0.50 mm
(0.0197 in)
0.115 mm
(0.0045 in)
0.80 mm
(0.0315 in)
0.115 mm
(0.0045 in)
ProCarManuals.com
Page 36 of 457
2-8
ENGINE SPECIFICATIONSSPEC
ItemStandardLimit
Connecting rods
Crankshaft-pin-to-big-end-bearing
clearance
Bearing color code
0.034 0.058 mm (0.0013 0.0023 in)
1 = Blue 2 = Black 3 = Brown 4 = Green0.09 mm
(0.0035 in)
Crankshaft
Width A
Width B
Max. runout C
Big end side clearance D
Crankshaft-journal-to-crankshaft-
journal-bearing clearance
Bearing color code
55.20 56.60 mm (2.17 2.23 in)
298.8 300.7 mm (11.76 11.84 in)
0.160 0.262 mm (0.0063 0.0103 in)
0.014 0.037 mm (0.0006 0.0015 in)
0 = White 1 = Blue 2 = Black
3 = Brown 4 = Green
0.03 mm
(0.0012 in)
0.10 mm
(0.0039 in)
ProCarManuals.com
Page 37 of 457
2-9
ENGINE SPECIFICATIONSSPEC
ItemStandardLimit
Clutch
Clutch type
Clutch release method
Clutch release method operation
Operation
Clutch cable free play (at the end
of the clutch lever)
Friction plates
Color code
Thickness
Plate quantity
Color code
Thickness
Plate quantity
Color code
Thickness
Plate quantity
Clutch plates
Thickness
Plate quantity
Max. warpage
Clutch springs
Free length
Spring quantity
Wet, multiple disc
Outer pull, rack and pinion pull
Cable operation
Left-hand operation
10 15 mm (0.39 0.59 in)
Purple
2.9 3.1 mm (0.114 0.122 in)
7
Green
2.9 3.1 mm (0.114 0.112 in)
1
–
2.9 3.1 mm (0.114 0.112 in)
1
1.9 2.1 mm (0.07 0.08 in)
8
52.5 mm (2.07 in)
6
2.8 mm
(0.110 in)
2.8 mm
(0.110 in)
2.8 mm
(0.110 in)
0.1 mm
(0.0039 in)
49.9 mm
(1.96 in)
ProCarManuals.com
Page 38 of 457
2-10
ENGINE SPECIFICATIONSSPEC
ItemStandardLimit
Transmission
Transmission type
Primary reduction system
Primary reduction ratio
Secondary reduction system
Secondary reduction ratio
Operation
Gear ratios
1st gear
2nd gear
3rd gear
4nd gear
5th gear
6th gear
Max. main axle runout
Max. drive axle runout
Constant mesh, 6-speed
Spur gear
65 / 43 (1.512)
Chain drive
45 / 17 (2.647)
Left-foot operation
38 / 15 (2.533)
33 / 16 (2.063)
37 / 21 (1.762)
35 / 23 (1.522)
30 / 22 (1.364)
33 / 26 (1.269)
0.08 mm
(0.0032 in)
0.08 mm
(0.0032 in)
Shifting mechanism
Shift mechanism type
Max. shift fork guide bar bending
Shift drum / Guide bar
0.10 mm
(0.0039 in)
Air filter typeOil coated paper element
Fuel pump
Pump type
Model (manufacturer)
Output pressure
Electrical
5PW (DENSO)
294 kPa (2.94 kg / cm
2, 2.94 bar, 42.6 psi)
Throttle position sensor
Resistance
Output voltage (at idle)
4.9 5.1 kΩ at 20C (68F)
0.63 0.73 V
Throttle bodies
Model (manufacturer) quantity
Intake vacuum pressure
Throttle cable free play (at the flange
45EIDW (MIKUNI) 2
22 kPa (165 mmHg, 6.4966 inHg)
3 5 mm (0.12 0.20 in)
of the throttle grip)
ID mark
Throttle valve size
5VY1 00 (USA)
5VY5 10 (CAL)
#100
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Page 44 of 457
2-16
ELECTRICAL SPECIFICATIONSSPEC
ItemStandardLimit
Indicator light
(voltage / wattage quantity)
Neutral indicator light
High beam indicator light
Oil level warning light
Turn signal indicator light
Fuel level warning light
Coolant temparture indicator light
Engine trouble warning light
Shift timing indicator light
LED 1
LED 1
LED 1
LED 2
LED 1
LED 1
LED 1
LED 1
Electric starting system
System type
Starter motor
Model (manufacturer)
Power output
Brushes
Overall length
Spring force
Armature coil resistance
Commutator diameter
Mica undercut
Constant mesh
5VY (YAMAHA)
0.9 kW
10.8 mm (0.43 in)
5.28 7.92 N (538 808 g,
18.99 28.48 oz)
0.0090 0.0110 Ω at 20C (68F)
24.5 mm (0.96 in)
1.5 mm (0.06 in)
3.6 mm
(0.14 in)
23.5 mm
(0.93 in)
Starter relay
Model (manufacturer)
Amperage
Coil resistance
2768079-A (JIDECO)
180 A
4.18 4.62 Ω at 20C (68F)
Horn
Horn type
Model (manufacturer) quantity
Max. amperage
Performance
Coil resistance
Plane
YF-12 (NIKKO) 1
3 A
105 113 db / 2 m
1.15 1.25 Ω at 20C (68F)
Turn signal relay
Relay type
Model (manufacturer)
Self-cancelling device built-in
Turn signal blinking frequency
Wattage
Full transistor
FE218BH (DENSO)
No
75 95 cycles / min.
21 W 2 + 3.4 W
Oil level switch
Model (manufacturer)
5VY (SOMIC ISHIKAWA)
EXUP servo motor
Model (manufacturer)
5VY (YAMAHA)
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