Suzuki 2009 LT-A500XP, Service Manual

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1D-68 Engine Mechanical:
Ca Cylinder Head
Unit: mm (in)
Cy Piston Ring
Unit: mm (in)
Crankshaft
Unit: mm (in)
Item Standard Limit
Cam height
IN. 33.45 – 33.50 (1.317 – 1.319) 33.15 (1.305)
EX. 33.47 – 33.52 (1.318 – 1.320) 33.17 (1.306)
Camshaft journal oil clearance
Camshaft
end side
0.028 – 0.059 (0.0011 – 0.0023)
0.150 (0.0059)
Other side 0.032 – 0.066 (0.0013 – 0.0026)
Camshaft journal holder I.D.
Camshaft
end side
17.512 – 17.525 (0.6894 – 0.6900)
—
Other side 22.012 – 22.025 (0.8666 – 0.8671)
Camshaft journal O.D.
Camshaft
end side
17.466 – 17.484 (0.6876 – 0.6883)
—
Other side 21.959 – 21.980 (0.8645 – 0.8654)
Camshaft runout — 0.10 (0.004)
Rocket arm I.D IN. & EX. 12.000 – 12.018 (0.4724 – 0.4731)
Rocket arm shaft O.D IN. & EX. 11.973 – 11.984 (0.4714 – 0.4718)
Cylinder head distortion — 0.05 (0.002)
Cylinder head cover distortion — 0.05 (0.002)
Item Standard Limit
Compression pressure (Automatic-
decomp. actuated)
Approx. 1 000 kPa (10.0 kgf/cm
2
, 142 psi) —
Piston-to-cylinder clearance 0.030 – 0.040 (0.0012 – 0.0016) 0.120 (0.0047)
Cylinder bore 87.500 – 87.515 (3.4449 – 3.4455)
Nicks or
Scratches
Piston diam.
87.465 – 87.480 (3.4435 – 3.4441)
Measure at 15 mm (0.6 in) from the skirt end.
87.380 (3.4402)
Cylinder distortion — 0.05 (0.002)
Piston ring free end gap
1st Approx. 6.2 (0.24) 4.9 (0.19)
2nd 2R Approx. 12.0 (0.47) 9.6 (0.38)
Piston ring end gap
1st 0.08 – 0.20 (0.003 – 0.008) 0.50 (0.020)
2nd 2R 0.10 – 0.25 (0.004 – 0.010) 0.50 (0.020)
Piston ring-to-groove clearance
1st — 0.180 (0.0071)
2nd — 0.150 (0.0059)
Piston ring groove width
1st
0.78 – 0.80 (0.0307 – 0.0315) —
1.30 – 1.32 (0.051 – 0.052) —
2nd 1.01 – 1.03 (0.040 – 0.041) —
Oil 2.51 – 2.53 (0.099 – 0.100) —
Piston ring thickness
1st
0.71 – 0.76 (0.028 – 0.030) —
1.08 – 1.10 (0.0425 – 0.0433) —
2nd 2R 0.97 – 0.99 (0.038 – 0.039) —
Piston pin bore I.D. 20.002 – 20.008 (0.7875 – 0.7877) 20.030 (0.7886)
Piston pin O.D. 19.992 – 20.000 (0.7871 – 0.7874) 19.980 (0.7866)
Item Standard Limit
Conrod small end I.D. 20.006 – 20.014 (0.7876 – 0.7880) 20.040 (0.7890)
Conrod deflection — 3.0 (0.12)
Conrod big end side clearance 0.10 – 0.65 (0.004 – 0.026) 1.0 (0.04)
Conrod big end width 24.95 – 25.00 (0.982 – 0.984) —
Crank web to web width 70.9 – 71.1 (2.79 – 2.80) —
Crankshaft runout — 0.08 (0.003)