2-5 PERIODIC MAINTENANCE

TAPPET CLEARANCE
I Inspect every 12,000 km.

• Remove the center leg shield and right and left leg shields.
(Refer to page 5-2.)
• Disconnect the spark plug cap and remove the spark plug.
• Remove the cylinder head cover.
The tappet clearance specification is different for intake and
exhaust valves.
Tappet clearance adjustment must be checked and adjusted,
1) at the time of periodic inspection
2) when the valve mechanism is serviced, and
3) when the camshafts are disturbed by removing them for
servicing.
Tappet clearance (when cold): IN. : 0.10-0.20 mm
Ex. : 0.20-0.30 mm
NOTE:
• The piston must be at Top Dead Center (TDC) on the compression
stroke in order to check the tappet clearance or to adjust
tappet clearance.
• The clearance specification is for COLD state.
3-21 ENGINE

• Compress the valve spring and remove the valve

cotters G) from the valve stem using the special tools.

1-Woh 09916-14510: Valve lifter

09916-14530: Valve lifter attachment
09916-84511: Tweezers

• Remove the valve spring retainer Cg), valve spring @ and

valve spring seat@.

• Remove the valve® from the combustion chamber side.

CYLINDER HEAD DISTORTION

Decarbonize the combustion chamber.
Check the gasket surface of the cylinder head for distortion
usin g a straightedge an d thickn ess gauge. Take clearance
readin gs at several places. If readin gs exceed the service
limit, replace the cylinder head.

1.fo§h 09900-20803: Thickness gauge

Service Limit: 0.05 mm

VALVE FACE WEAR

The thickness of the valve face decreases as the face wears.
Visually inspect each valve face for wear and replace any
valve with an abnormally worn face. Measure the valve
face thickness (I). If it is out of specification, replace the
valve with a new one.

1-fuoh 09900-20101: Vernier calipers

Standard: 0.80mm - 0.60mm
Service Limit: 0.5 mm
 3-25 ENGINE

If the contact area is too low or too narrow, use the 45° cut­
Contact area too high and too wide
ter to raise and widen the contact area. on face of valve
• After the desired seat position and width is achieved, use
the 45° cutter very lightly to clean up any burrs caused
by the previous cutting operations.

I A CAUTION[
DO NOT use lapping compound after the final cut is
made. The finished valve seat should have a velvety
smooth finish and not a highly polished or shiny fin­
ish. This will provide a soft surface for the final seat­
Contact area too low and too narrow
ing of the valve which will occur during the first few on face of valve
seconds of engine operation.

• Clean and assemble the head and valve components. Fill

the intake and exhaust ports with gasoline to check for
leaks. If any leaks occur, inspect the valve seat and face
for burrs or other things that could prevent the valve
from sealing.

A WARNING
Always use extreme caution when handling gasoline.

NOTE:
After servicing the valve seats, be sure to check the tappet
.,.,, clearance after the cylinder has been reinstalled. (See pp.
2-5 ff•. )

VALVE SPRINGS
Check the valve springs for proper strength by measuring
their free length and also the force required to compress
them. If the spring length is less than the service limit or if
the force required to compress the spring does not fall
within the specified range, replace the spring.

1.f&ih 09900-20201: Vernier calipers

Standard
Valve spring free length: 38.25mm - 36.35mm

Standard 12.0-14.0
Valve spring tension: 12.0-14.0 kg/33.7 mm ◊
 3-27 ENGINE

• Install the valve spring retainer G), press down the

spring using the valve lifter and then install the cotter
halves onto the valve stem end. Then, release the valve
lifter to allow the cotter® to wedge between the retainer
and the valve stem. Be sure that the rounded lip@ of the
cotter fits snugly into the groove@ in the stem end.

nijh 09916-14510: Valve lifter

09916-14530: Valve lifter attachment
09916-84511: Tweezers

I A CAUTION I
Be sure to install all of the parts in their original posi­
tions.

NOTE:
Apply engine oil to the tappet shim and tappet before
installing them.

CAMSHAFT
CAMSHAFT INSPECTION
If the engine produces abnormal noises, vibration or lacks
power, a camshaft may be distorted or worn to the service
t'1 limit. The camshaft runout should be checked. Also, check
the cams and journals for wear or damage.
The exhaust camshaft has the embossed letters "EX" and
the intake camshaft has the embossed letters "IN".

CAM WEAR
Worn-down cams are often the cause of mistimed valve
operation resulting in reduced power output.
Measure the cam height (8) using the micrometer. Replace
H
a camshaft if the cams are worn to the service limit.

1filih 09900-20202: Micrometer (25-50 mm)

STANDARD
Cam height (8) IN: 34.980mm - 35.020mm
EX: 34.180mm - 34.220mm
 3-25 ENGINE

CAM SPROCKET
When installing each cam sprocker to the each camshaft,
on the contrary notch(D and arrow mark No. 2@ on INTAKE
camshaft, or notch @ and arrow mark No.1 and 3
@) on EXHAUST camshaft.
• Apply THREAD LOCK SUPER "1303" to the threads of cam
sprocket bolts. and tighten them to the specified torque.

� 99000-32030 : THREAD LOCK SUPER "1303"

� Sprocket bolt : 11 N-m (1.1 kg-m)

CAM CHAIN TENSION ADJUSTER

The cam chain tension adjuster is maintained at the
propertension by an automatically adjusted tensioner.
Insert the 0 screwdriver into the slotted end of cam chain
tension adjuster and turn it clockwise to lessen the tension
and release the 0 screwdriver from the cam chain tension
adjuster. to make sure the push rod movement. If the push rod
is stuck or spring mechanism failed, replace the cam chain
tension adjuster assembly with a new one.

CYLINDER
DISTORTION
Check the gasketed surface of the cylinder for distortion with
a straightedge and thickness gauge. taking a clearance reading
at several places as indicated. If the largest reading at any
position of the straightedge exceeds the limit, replace the cylinder.
Service Limit : 0.05 mm
lr'foh 09900-20803 : Thickness gauge
CYLINDER BORE
Measure the cylinder bore diameter at six places.
If any one of the measurements exceeds the limit, overhaul the
cylinder and replace the piston with an oversize. or replace the
cylinder.
Standard : 62.00mm - 62.06mm
Service limit : 62.10mm

-
S 09900-20508 : Cylinder bore gauge set .

I
 ENGINE3-26

PISTON AND PISTON PIN

DIAMETER
Using a micrometer. measure the piston outside diameter at
the place 15 mm from the skirt end as shown in Fig. If the
measurement is less than the limit, replace the piston.
Standard : 61.975mm -- 61.990mm

Service limit : 61.903mm

__JS mm.
Piston oversize: 0.5, 1.0 mm

1-fuoh 09900- 20203 : Micrometer (50- 75 mm)

PISTON-CYLINDER CLEARANCE
As a result of the above measurement, if the piston to cylinder
clearance exceeds the following limit, overhaul the cylinder
and use an oversize piston, or replace both cylinder and piston.
Service Limit: 0.120 mm

PISTON RING-GROOVE CLEARANCE

Using a thickness gauge, measure the side clearance of the
1st and 2nd rings. If any of the clearances exceeds the limit,
replace both piston and piston rings.
Piston ring-groove clearance
Service Limit 1st : 0.18 mm
2nd: 0.15 mm
Piston ring groove width
Standard: 1st 1.01-1.03 mm
2nd : 1.01-1.03 mm
Oil : 2.01-2.03 mm
Piston ring thickness
Standard 1st and 2nd : 0.97-0.99 mm

1-ffiiih 09900- 20803 : Thickness gauge

09900-20205 : Micrometer (0-25 mm)

NOTE:
Using a soft-metal scraper, decarbon the crown of the piston.
Clean the ring grooves similarly.

PISTON RING END GAP

Fit the ring in the cylinder, and measure each ring end gap
using a thickness gauge.
If any ring has an excess end gap, replace the ring.
Piston ring end gap
Standard : 1st 0.10mm - 0.22mm
: 2nd 0.10mm - 0.22mm

1.ffioh 09900-20803 : Thickness gauge

3-27 ENGINE

PIN BORE
Using a caliper gauge, measure the piston pin bore inside
diameter, and using a micrometer measure the piston pin outside
diameter. If the difference between these two measurements is
more than the limits, replace both piston and piston pin.
Piston pin bore
Standard : 16.006mm - 16.024mm

Piston pin O.D.

Standard : 15.996mm - 16.000mm

liil};J 09900-20605 : D ial calipers

09900-20205 : Micrometer (0-25 mm)
 ENGINE 3-28

CRANKSHAFT AND CONROD

CONROD INSPECTION
CONROD SMALL END I.D.
• Using a caliper gauge, measure the conrod small end inside
diameter.
Standard : 16.006mm - 16.024mm

j·/iiiilj 09900-20605 : Dial calipers

If the conrod small end bore inside diameter exceeds the limit,
replace conrod.
3-29 ENGINE

CONROD DEFLECTION AND CONROD BIG END SIDE

CLEARANCE
Wear on the big end of the conrod can be estimated by
checking the movement of the small end of the rod. This
method can also check the extent of wear on the parts of the
conrod's big end.

S
Service Limit : 3.0 mm
09900-20701 : Magnetic stand
09900-20606 : Dial gauge (1/100 mm)
09900-21304 : V-block
Push the big end of the conrod to one side and measure the
side clearance with a thickness gauge.
Standard : 0.10-0.45 mm
Service Limit : 1.00 mm
j+fotj 09900-20803 : Thickness gauge
Where the limit is exceeded, replace crankshaft assembly or
reduce the deflection and the side clearance to within the limit
by replacing the worn parts-conrod. big end bearing and crank
pin etc.

CRANKSHAFT INSPECTION
CRANKSHAFT RUNOUT
Support the crankshaft with "V" blocks as shown, with the two
end journals resting on the blocks. Position the dial gauge, as
shown, and rotate the crankshaft slowly to read the runout.
Correct or replace the crankshaft if the runout is greater than
the limit.
Standard : 0.00 - 0.07mm
Service Limit : 0.08 mm

REASSEMBLY
• Decide the width between the webs referring to the figure
below when rebuilding the crankshaft.
Standard width between webs : 53.0 :': 0.1 mm

53.0 :': 0.1 mm

 ENGINE 3-34

GEAR SHIFT FORK

Using a thickness gauge, check ·the shift fork clearance in the
groove of its gear.
This clearance for each of the two shift forks plays an important
role in the smoothness and positiveness of shifting action.
Each fork has its prongs fitted into the annular groove provided
in its gear. In operation, there is sliding contact b etween fork
and gear and, when a shifting action is initiated, the fork plushes
the gear axially. Too much a clearance is, therefore, liable to
cause the meshed gears to slip apart.
If the clearance checked is noted to exceed the limit specified,
replace the fork or its gear, or both.

S 09 9 00-20803: Thickness gauge

Shift fork-roove clearance

Standard : 0.1 mm - 0.3mm

Shift fork groove width

Standard No.1 : 5.0-5.1 mm
No.2 : 5.5-5.6 mm

Shift fork thickness

Standard No.1 : 4.8-4.9 mm

No.2 : 5.3-5.4 mm

PRIMARY DRIVE GEAR

DISASSEMBLY
• Remove the primary drive gear from primary shaft.

• Install the key, primary gear, washer, spring washer and nut.
3-35 ENGINE

CLUTCH
CLU TCH DRIVE PLATE
Measure the thickness of each drive plate with vernier calipers.
Replace drive plates found to have worn down to the limit.
Standard - Thickness : 3.10mm - 2.70mm
Claw width: 11.8mm - 12.0mm

S 09900-20102: Vernier calipers

CLUTCH DRIVEN PLATE

Measure each driven plate for distortion with a thickness gauge.
Replace driven plates which exceed the limit.
Seivice Limit: 0.15 mm
liiJ 09900-20803 : Thickness gauge

CLUTCH SPRING FREE LENGTH

Measure the free length of each coil spring with a
vernier calipers. and determine the elastic strength of each.
Replace any spring not within the limit.
Standard : 31.10mm - 28.09mm
liiJ 09900-20102 : Vernier calipers

CLUTCH RELEASE BEARING

Inspect the release bearing for any abnormality, particularly
cracks, to decide whether it can be reused or should be
replaced.
Smooth engagement and disengagement of the clutch
depends much on the condition of this bearing.
 SERVICING INFORMATION 7-22

SERVICE DATA
VALVE + GUIDE Unit: mm.

Valve diam. IN. 22

EX. 19
Tappet clearance (when cold) IN. 0.10 - 0.20
EX. 0.20 - 0.30
Valve guide to valve stem IN. 0.010 - 0.037
Clearance EX. 0.030 - 0.057
Valve stem deflection IN. & EX. 0.35
Valve guide I.D. IN. & EX. 4.500 - 4.512
Valve stem O.D. IN. 4.475 - 4.490
EX 4.455 - 4.470
Valve stem runout IN. & EX. 0.05
Valve head thickness IN. & EX. 0.5
Valve seat width IN. & EX. 1.10 - 0.90
Valve head radial runout IN. & EX. 0.03
Valve spring free length IN. & EX. 36.35
Valve spring tension IN. & EX. 12.1-13.9 kg.I
at length 33.7 mm.

CAMSHAFT + CYLINDER HEAD Unit: mm.

Cam height IN. 34.980-35.020 34.660

EX. 34.180-34.220 34.377
Camshaft journal oil clearance IN. & EX. 0.032-0.066 0.150
Camshaft journal holder I.D. IN. & EX. 22.012-22.025
Camshaft journal O.D. IN. & EX. 21.959-21.980
Camshaft runout IN. & EX. 0.10
Cam chain pin (at arrow "3") 16th pin
Cylinder head distortion 0.05

CYLINDER + PISTON + PISTON RING Unit: mm.

Piston to cylinder clearance 0.050-0.060 0.120

Cylinder bore 62.00-62.06 62.10
Piston diam. 61.97-61.99 61.90
Measure at 15 mm from the skirt end.
Cylinder distortion 0.05
Piston ring free end gap 1st R Ap prox. 8.5 6.8
2nd R Approx. 6.5 5.2
Piston ring end gap 1st 0.10-0.22 0.34
2nd 0.10-0.22 0.34
7-23 SERVICING INFORMATION

Piston ring to groove clearance 1st 0.18

2nd 0.15
Piston ring groove width 1st 1.01-1.03
2nd 1.01-1.03
Oil 2.01-2.03
Piston ring thickness 1st 0.97-0.99
2nd 0.97-0.99
Piston pin bore 16.006-16.024 16.030
Piston pin O.D. 15.996-16.000 15.980

CONROD + CRANKSHAFT Unit: mm.

Conrod small end I.D. 16.006-16.024 16.040

Conrod deflection 3.0
Conrod big end side clearance 0.10-0.45 1.00
Conrod big end width 16.950-17 .000
Crank web to web width 53.0 :': 0.1
Crankshaft runout 0.08

OIL PUMP

Oil pump reduction ratio 2.000 (30/15)

° °
Oil pressure (at 60 C, 140 F) Above 30 kPa (0.3 kg/cm2)
Below 50 kPa (0.5 kg/cm2)
at 3.000 r/min.

CLUTCH Unit: mm.

Clutch lever play 10-15

Drive plate thickness 3.10-2.70 2.60
Drive plate claw width 11.8-12.0 11.0
Driven plate distortion 0.15
Clutch spring free length 31.0