2006r Service data.pdf

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SERVICE DATA
4 STROKE
VALVE + GUIDE
ITEM
Valve diam.
IN.
EX.
Tappet clearance (when cold)
IN.
EX.
Valve guide to valve stem
clearance
IN.
EX.
Valve stem deflection
Valve guide I.D.
Valve stem O.D.
IN. & EX.
IN. & EX.
IN.
EX.
Valve stem runout
Valve seat width
Valve head radial runout
Valve spring free length
IN. & EX.
IN. & EX.
IN. & EX.
IN.
EX.
Valve spring tension
IN.
EX.
STANDARD
36
(1.42)
29
(1.14)
0.15 – 0.20
(0.005 – 0.007)
0.17 – 0.23
(0.006 – 0.009)
0.010 – 0.037
(0.0004 – 0.0015)
0.030 – 0.057
(0.0012 – 0.0022)
—
5.000 – 5.012
(0.1968 – 0.1973)
4.975 – 4.990
(0.1959 – 0.1965)
4.955 – 4.970
(0.1951 – 0.1957)
—
0.9 – 1.1
(0.035 – 0.043)
—
—
—
128 N (13 kgf, 28.7 lbs)
at length 30.9 mm (12.2 in)
78.5 N (8 kgf, 17.6 lbs)
at length 30.9 mm (12.2 in)
Date: September 27, 2005
Model: RM-Z450K6
Unit: mm (in)
LIMIT
—
—
—
—
—
—
0.25
(0.010)
—
—
—
0.05
(0.002)
—
0.03
(0.001)
34.0
(1.34)
33.3
(1.31)
—
—
Model: RM-Z450K6
1/7
E-03, 28
CAMSHAFT + CYLINDER HEAD
ITEM
Cam height
IN.
EX.
Camshaft journal oil clearance
Camshaft journal holder I.D.
Camshaft journal O.D.
Camshaft runout
Cam chain pin
Cylinder head distortion
Cylinder head cover distortion
IN. & EX.
IN. & EX.
IN. & EX.
STANDARD
33.29 – 33.59
(1.31 – 1.32)
32.50 – 32.80
(1.27 – 1.29)
0.032 – 0.066
(0.001 – 0.002)
22.012 – 22.025
(0.8667 – 0.8671)
21.959 – 21.980
(0.864 – 0.865)
—
15th pin
—
—
Unit: mm (in)
LIMIT
32.99
(1.30)
32.20
(1.27)
0.150
(0.0059)
—
—
0.10
(0.004)
—
0.05
(0.002)
0.05
(0.002)
Unit: mm (in)
LIMIT
—
0.120
(0.0047)
Nicks or
scratches
95.380
(3.7551)
0.05
(0.002)
10.2
(0.40)
0.50
(0.020)
0.180
(0.007)
—
—
—
19.030
(0.7492)
18.980
(0.7472)
CYLINDER + PISTON + PISTON RING
ITEM
Compression pressure
(Automatic decomp. actuated)
Piston to cylinder clearance
Cylinder bore
Piston diam.
Cylinder distortion
Piston ring free end gap
Piston ring end gap
Piston ring to groove clearance
Piston ring groove width
1st
1st
1st
1st
Oil
Piston ring thickness
Piston pin bore
Piston pin O.D.
1st
R
STANDARD
430 – 720 kPa
(4.3 – 7.2 kgf/cm
2
, 61 – 102 psi)
0.030 – 0.040
(0.0012 – 0.0016)
95.500 – 95.515
(3.7598 – 3.7604)
95.465 – 95.480
(3.7584 – 3.7590)
Measure at 15 mm (0.6 in) from the skirt end.
—
Approx. 12.8
(0.50)
0.08 – 0.20
(0.003 – 0.008)
—
1.21 – 1.23
(0.0476 – 0.0484)
2.01 – 2.03
(0.0791 – 0.0799)
1.17 – 1.19
(0.0461 – 0.0469)
19.002 – 19.008
(0.7481 – 0.7483)
18.995 – 19.000
(0.7478 – 0.7480)
Model: RM-Z450K6
2/7
E-03, 28
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
Conrod deflection
Conrod big end side clearance
Conrod big end width
Crank web to web width
Crankshaft runout
STANDARD
19.010 – 19.018
(0.7484 – 0.7487)
—
0.20 – 0.65
(0.008 – 0.026)
19.75 – 19.80
(0.778 – 0.780)
62 ± 0.1
(2.44 ± 0.004)
—
Unit: mm (in)
LIMIT
19.040
(0.7496)
3.0
(0.12)
1.0
(0.04)
—
—
0.08
(0.003)
OIL PUMP
ITEM
Oil pump reduction ratio
Oil pressure (at 50 °C, 122 °F)
STANDARD
2.099 (62/24 × 13/16)
50 kPa (0.5 kgf/cm
2
, 7.1 psi)
at 1 950 r/min
LIMIT
—
—
CLUTCH
ITEM
Clutch cable play
Drive plate thickness
(No.1 & No.2)
Drive plate claw width
(No.1 & No.2)
Driven plate distortion
Clutch spring free length
STANDARD
10 – 15
(0.4 – 0.6)
3.07 – 3.23
(0.121 – 0.127)
13.85 – 13.95
(0.545 – 0.549)
—
50.83
(2.00)
Unit: mm (in)
LIMIT
—
2.77
(0.109)
13.05
(0.512)
0.10
(0.004)
48.3
(1.90)
RADIATOR + ENGINE COOLANT
ITEM
Radiator cap valve opening
pressure
Engine coolant type
STANDARD/SPECIFICATION
95 – 125 kPa
(0.95 – 1.25 kgf/cm², 14 – 18 psi)
Use an anti-freeze/coolant compatible with alumi-
num radiator, mixed with distilled water only, at the
ratio of 50:50.
1 000 ml
(1.1/0.9 US/lmp qt)
LIMIT
—
—
—
Engine coolant capacity
Model: RM-Z450K6
3/7
E-03, 28
TRANSMISSION + DRIVE CHAIN
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratios
STANDARD
2.583 (62/24)
3.500 (49/14)
2.000 (30/15)
1.611 (29/18)
1.350 (27/20)
1.136 (25/22)
0.05 – 0.25
(0.002 – 0.010)
4.95 – 5.05
(0.195 – 0.199)
4.80 – 4.90
(0.188 – 0.193)
D.I.D 520 MXV
114
15.0 (0.59)
12.8 (0.50)
40 – 50
(1.57 – 1.97)
Unit: mm (in) Except ratio
LIMIT
—
—
—
—
—
—
0.45
(0.018)
—
—
—
—
12.75
(0.502)
11.20
(0.441)
—
Low
2nd
3rd
Top
Shift fork to groove clearance
Shift fork groove width
Shift fork thickness
Drive chain
Drive chain plate height
No.1, No.2
No.1, No.2
No.1, No.2
Type
Links
Inner
Outer
Drive chain slack
CARBURETOR
ITEM
Carburetor type
Bore size
I.D. No
Idle r/min
Float height
Fuel level
Main jet
Jet needle
Slow jet
Slow air jet
Starter jet
Pilot screw
Leak jet
Idle adjust screw
Throttle cable play
(pulling cable)
(M.J.)
(J.N.)
(S.J.)
(S.A.J)
SPECIFICATION
E-03, 000
FCR40MX
40 mm
(15.7 in)
35G2
1 950 ± 100 r/min
8 mm
(0.31 in)
6.5 mm (0.26 in)
(Above the datum point)
#170
NCYR-3rd
#42
#100
#75
1 and 3/4 turns back
#35
Adjust to the specified idle speed.
2 – 4 mm
(0.08 – 0.16 in)
E-28
←
←
35G3
←
←
←
#175
←
←
←
←
←
←
←
←
Model: RM-Z450K6
4/7
E-03, 28
ELECTRICAL
ITEM
Ignition timing
Spark plug
Spark performance
Pick-up coil resistance
Exciter coil resistance
Charge coil resistance
Pick-up peak voltage
Exciter peak voltage
Charge peak voltage
Ignition coil resistance
Ignition coil primary peak voltage
Type
Gap
SPECIFICATION
8° B.T.D.C. at 1 950 r/min.
NGK: CR8EIB-10
0.9 – 1.0 (0.035 – 0.039)
Over 8 (0.3) at 1 atm.
72 – 127
Ω
24 – 40
Ω
1.6 – 3.2
Ω
2 V and more
25 V and more
Primary
Secondary
8 V and more
0.17 – 0.70
Ω
9 – 14 kΩ
200 V and more
Unit: mm (in)
NOTE
R–G
B/R – R/W
Y – B/W
+
R–
-
G
+
B/R –
-
R/W
+
Y –
-
B/W
W/Bl – B/W
Plug cap – B/W
+
B/W –
-
W/Bl
Unit: mm (in)
BRAKE + WHEEL
ITEM
Brake lever adjuster length
Rear brake pedal height
Brake disc thickness
Front
Rear
Brake disc runout
Master cylinder bore
Front &
Rear
Front
Rear
Master cylinder piston diam.
Front
Rear
Brake caliper cylinder bore
Front
Rear
Brake caliper piston diam.
Front
Rear
Brake fluid type
Wheel rim runout
STANDARD
11 – 15
(0.4 – 0.6)
0 – 10
(0 – 0.4)
3.0 ± 0.2
(0.118 ± 0.008)
4.0 ± 0.15
(0.157 ± 0.006)
—
11.000 – 11.043
(0.4331 – 0.4348)
11.000 – 11.043
(0.4331 – 0.4348)
10.957 – 10.984
(0.4314 – 0.4324)
10.957 – 10.984
(0.4314 – 0.4324)
27.000 – 27.050
(1.0630 – 1.0650)
25.400 – 25.450
(1.0000 – 1.0020)
26.900 – 26.950
(1.0591 – 1.0610)
25.335 – 25.368
(0.9974 – 0.9987)
DOT 4
—
—
LIMIT
—
—
2.5
(0.10)
3.5
(0.14)
0.3
(0.012)
—
—
—
—
—
—
—
—
2.0
(0.08)
2.0
(0.08)
Axial
Radial
Model: RM-Z450K6
5/7
E-03, 28

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