GENERAL INFORMATION
1-10
CRANKCASE/TRANSMISSION SPECIFICATIONS
Unit: mm (in)
CRANKSHAFT/PISTON/CYLINDER SPECIFICATIONS
Unit: mm (in)
ITEM
STANDARD
SERVICE LIMIT
Shift fork,
fork shaft
I.D.
12.000 – 12.021 (0.4724 – 0.4733)
12.03 (0.474)
Claw thickness
5.93 – 6.00 (0.233 – 0.236)
5.9 (0.23)
Shift fork shaft O.D.
11.957 – 11.968 (0.4707 – 0.4712)
11.95 (0.470)
Transmission
Gear I.D.
M5,M6
28.000 – 28.021 (1.1024 – 1.1032)
28.04 (1.104)
C2, C3, C4
31.000 – 31.025 (1.2205 – 1.2215)
31.04 (1.222)
Gear busing O.D.
M5, M6
27.959 – 27.980 (1.1007 – 1.1016)
27.94 (1.100)
C2, C3, C4
30.950 – 30.975 (1.2189 – 1.2197)
30.94 (1.218)
Gear-to-bushing
clearance
M5, M6
0.020 – 0.062 (0.0008 – 0.0024)
0.10 (0.004)
C2, C3, C4
0.025 – 0.075 (0.0010 – 0.0030)
0.11 (0.004)
Gear bushing I.D.
M5
24.985 – 25.006 (0.9837 – 0.9845)
25.016 (0.9849)
C2
27.985 – 28.006 (1.1018 – 1.1026)
28.021 (1.1032)
Mainshaft O.D.
at M5
24.967 – 24.980 (0.9830 – 0.9835)
24.96 (0.983)
Countershaft O.D.
at C2
27.967 – 27.980 (1.1011 – 1.1016)
27.96 (1.101)
Bushing to shaft
clearance
M5
0.005 – 0.039 (0.0002 – 0.0015)
0.06 (0.002)
C2
0.005 – 0.039 (0.0002 – 0.0015)
0.06 (0.002)
ITEM
STANDARD
SERVICE LIMIT
Crankshaft
Connecting rod side clearance
0.15 – 0.30 (0.006 – 0.012)
0.35 (0.014)
Crankpin bearing oil clearance
0.028 – 0.052 (0.0011 – 0.0020)
0.06 (0.002)
Main journal bearing oil clearance
0.020 – 0.038 (0.0008 – 0.0015)
0.05 (0.002)
Runout
–
0.05 (0.002)
Piston, piston
rings
Piston O.D. at 6 (0.2) from bottom
66.965 – 66.985 (2.6364 – 2.6372)
66.90 (2.634)
Piston pin bore I.D.
16.002 – 16.008 (0.6300 – 0.6302)
16.02 (0.631)
Piston pin O.D.
15.994 – 16.000 (0.6297 – 0.6299)
15.98 (0.629)
Piston-to-piston pin clearance
0.002 – 0.014 (0.0001 – 0.0006)
0.04 (0.002)
Piston ring end
gap
Top
0.10 – 0.20 (0.004 – 0.008)
0.4 (0.02)
Second
0.21 – 0.31 (0.008 – 0.012)
0.5 (0.02)
Oil
(side rail)
0.2 – 0.7 (0.01 – 0.03)
1.0 (0.04)
Piston ring-to-ring
groove clearance
Top
0.030 – 0.060 (0.0012 – 0.0024)
0.10 (0.004)
Second
0.015 – 0.050 (0.0006 – 0.0020)
0.08 (0.003)
Cylinder
I.D.
67.000 – 67.015 (2.6378 – 2.6384)
67.10 (2.642)
Out of round
–
0.10 (0.004)
Taper
–
0.10 (0.004)
Warpage
–
0.10 (0.004)
Cylinder-to-piston clearance
0.015 – 0.050 (0.0006 – 0.0022)
0.10 (0.004)
Connecting rod small end I.D.
16.030 – 16.044 (0.6311 – 0.6317)
16.05 (0.632)
Connecting rod-to-piston pin clearance
0.030 – 0.050 (0.0012 – 0.0020)
0.07 (0.003)
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys.
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