Honda TRX400EX FOURTRAX 1999, Service Manual

Page: 11 / 263

GENERAL INFORMATION
ITEM
Cylinder
I.D.
Out of round
STANDARD SERVICE LIMIT
85.000
-
85.010 (3.3465
-
3.3468)
85.10 (3.350)
0.05
Piston,
Taper 0.05
0.10
Piston O.D. at 15 (0.6) from bottom 84.960
-
84.985 (3.3449
-
3.3459)
84.880
Piston-to-piston pin clearance
- 0.014 (0.0001
-
0.0006)
- 0.35 (0.008 - 0.014)
0.096 (0.0038)
0.50
Piston ring end gap
Piston pin O.D. 19.994
-
20.000 (0.7872
-
0.7874)
19.964
Second
0.35
-
0.50 (0.014 - 0.020) 0.65
Clutch
Piston ring-to-ring
groove clearance
Oil (side
0.90
0.030
-
0.065 (0.0012
-
0.0026) 0.14
Second 0.015
-
0.050 (0.0006
-
0.0020) 0.12
-
0.70 (0.008
-
0.028)
Cylinder-to-piston clearance
Connecting rod small end
rod-to-Diston clearance
Outer guide
0.01 5
-
0.050 (0.0006
-
0.0020)
20.020
-
20.041 (0.7882 - 0.7890)
- 0.047 10.0008
-
0.10 (0.004)
20.067 (0.7900)
0.103
22.05 (0.868)
I.D.
O.D. (1.1007- 1.1016) 27.90
22.010
-
22.035 (0.8665 - 0.8675)
ITEM
O.D. a t clutch outer
21.959
-
21.980 (0.8645
-
0.8654)
21.91
STANDARD SERVICE LIMIT
Lever free play
Spring free length
Disc thickness
10
-
20
-
52.64 50.0
2.92
-
3.08 15
- 2.69
Plate 0.15
Outer I.D. 28.000-28.021
28.04
ITEM
Starter driven gear boss O.D.
STANDARD SERVICE LIMIT
51.705
-
51.718 (2.0356 - 2.0361) 51.67