2-3
SPEC
E
MAINTENANCE SPECIFICATIONS
MAINTENANCE SPECIFICATIONS
ENGINE
Item
Unit
Model
XLT800
CYLINDER HEAD
Warpage limit
mm (in)
0.1 (0.004)
Compression pressure
*1
kPa
(kg/cm
2
)
560 (5.6)
CYLINDERS
Bore size
mm (in)
80.000–80.018 (3.1496–3.1503)
Taper limit
mm (in)
0.08 (0.003)
Out-of-round limit
mm (in)
0.05 (0.002)
Wear limit
mm (in)
Original cylinder bore + 0.04 (0.0016)
PISTONS
Diameter
mm (in)
Red: 79.899–79.902 (3.1456–3.1457)
Orange: 79.903–79.906 (3.1458–3.1459)
Green: 79.907–79.910 (3.1459–3.1461)
Purple: 79.911–79.914 (3.1461–3.1462)
Measuring point*
mm (in)
22 (0.87)
Piston-to-cylinder clearance
mm (in)
0.100–0.105 (0.0039–0.0041)
Wear limit
mm (in)
Cylinder bore – 0.105 (0.0041)
Piston pin bore inside
diameter
mm (in)
22.004–22.025 (0.8663–0.8671)
PISTON RINGS
Top
Type
Keystone
Dimensions (B)
mm (in)
1.2 (0.05)
Dimensions (T)
mm (in)
2.85 (0.112)
End gap
mm (in)
0.30–0.45 (0.012–0.018)
Ring groove clearance
mm (in)
0.03–0.05 (0.001–0.002)
2nd
Type
Keystone
Dimensions (B)
mm (in)
1.2 (0.05)
Dimensions (T)
mm (in)
2.85 (0.112)
End gap
mm (in)
0.30–0.45 (0.012–0.018)
Ring groove clearance
mm (in)
0.03–0.05 (0.001–0.002)
PISTON PINS
Diameter
mm (in)
21.995–22.000 (0.8659–0.8661)
Wear limit
mm (in)
21.990 (0.8657)
CRANKSHAFT ASSEMBLY
Crank width
A
mm
(in)
72.95–73.00 (2.872–2.874)
Deflection limit
B
mm (in)
0.05 (0.002)
Big end side clearance
C
mm
(in)
0.25–0.75 (0.010–0.030)
Maximum small end axial
play
D
mm (in)
2.0 (0.08)
* 1: At 1,013 hPa and 20 °C (68°F)