1PP ENGINE MECHANICAL SERVICE DATA

Table 1. ENGINE
Compression	Pressure difference between each cylinder	500 kPa (5.1 kgf/cm², 73 psi) or less

Table 2. VALVE CLEARANCE
Valve clearance (cold)		Standard	Intake	0.160 to 0.260 mm (0.00630 to 0.01024 in.)
			Exhaust	0.350 to 0.430 mm (0.01378 to 0.01693 in.)
Adjust valve clearance	Valve clearance (cold)	Intake side	0.21 mm (0.0083 in.)
		Exhaust side	0.38 mm (0.0150 in.)

Table 3. ENGINE UNIT
Camshaft	Runout	Maximum	0.008 mm (0.000314 in.)
	Cam lobe height	Standard	41.6 mm (1.64 in.)
	Journal diameter	Journals	Standard	23.959 to 23.98 mm (0.943 to 0.944 in.)
	Cam lift	Standard	8.6 mm (0.339 in.)
No. 2 camshaft	Runout	Maximum	0.008 mm (0.000314 in.)
	Cam lobe height	Standard	51.5 mm (2.03 in.)
	Journal diameter	Journals	Standard	23.959 to 23.98 mm (0.943 to 0.944 in.)
	Cam lift	Standard	5.15 mm (0.203 in.)

Table 4. CYLINDER HEAD
Cylinder head sub-assembly	Warpage	Bottom side	Maximum	0.05 mm (0.00197 in.)
		Intake manifold side	Maximum	0.05 mm (0.00197 in.)
		Exhaust manifold side	Maximum	0.05 mm (0.00197 in.)
	Camshaft bearing diameter	Standard	24.0 to 24.1 mm (0.945 to 0.949 in.)
Inner compression spring	Height not under load Height not under load	Standard	47.2 mm (1.86 in.)
	Height under load 1.75 N	Standard	31.5 mm (1.24 in.)
	Height under load 2.87 N	Standard	23.0 mm (0.906 in.)
	Spring diameter at the top	Standard	16.1 mm (0.634 in.)
	Spring wire diameter	Standard	2.6 mm (0.102 in.)
	Spring diameter at the base	Standard	20.9 mm (0.823 in.)
Intake valve	Length	Standard	92.57 mm (3.64 in.)
	Diameter	Standard	4.970 to 4.985 mm (0.1957 to 0.1963 in.)
	Height	Standard	2.92 mm (0.115 in.)
	Angle	Standard	44°10' to 44°20'
	Diameter	Standard	29.02 to 29.22 mm (1.143 to 1.150 in.)
Exhaust valve	Length	Standard	91.85 mm (3.62 in.)
	Diameter	Standard	4.9525 to 4.9675 mm (0.1950 to 0.1956 in.)
	Height	Standard	2.97 mm (0.117 in.)
	Angle	Standard	43°52' to 44°92'
	Diameter	Standard	25.9 to 26.1 mm (1.020 to 1.028 in.)
Valve guide bush	Diameter	Standard	5.000 to 5.015 mm (0.1969 to 0.1974 in.)
	Height	Intake side	Standard	8.6 to 10.0 mm (0.339 to 0.394 in.)
		Exhaust side	Standard	8.1 to 9.5 mm (0.319 to 0.374 in.)
Intake valve seat	Width	Standard	1.0 to 1.4 mm (0.0394 to 0.0551 in.)
Exhaust valve seat	Width	Standard	1.2 to 1.6 mm (0.0472 to 0.063 in.)
Camshaft thrust clearance	Thrust clearance	Intake side	Minimum	0.1 mm (0.00394 in.)
			Maximum	0.2 mm (0.00787 in.)
		Exhaust side	Minimum	0.1 mm (0.00394 in.)
			Maximum	0.2 mm (0.00787 in.)

Table 5. CYLINDER BLOCK
Crankshaft thrust clearance		Standard	0.07 to 0.42 mm (0.00276 to 0.0165 in.)
Standard crankshaft thrust washer thickness		Standard	2.35 mm (0.0925 in.)
Cylinder block sub-assembly warpage		Maximum	0.05 mm (0.00197 in.)
Cylinder bore diameter		Standard	75.000 to 75.018 mm (2.95275 to 2.95346 in.)
Piston diameter	A	Standard	74.969 to 74.979 mm (2.95153 to 2.95192 in.)
Piston diameter	B	Standard	74.944 to 74.952 mm (2.95055 to 2.95086 in.)
Piston ring thickness	No. 1 compression ring	Standard	0.97 to 0.99 mm (0.0382 to 0.0390 in.)
	No. 2 compression ring	Standard	0.97 to 0.99 mm (0.0382 to 0.0390 in.)
	Oil ring	Standard	1.97 to 1.99 mm (0.0776 to 0.0783 in.)
Piston ring end gap	No. 1 compression ring	Standard	0.18 to 0.28 mm (0.00709 to 0.0110 in.)
	No. 2 compression ring	Standard	0.4 to 0.6 mm (0.0157 to 0.0236 in.)
	Oil ring	Standard	0.2 to 0.4 mm (0.00787 to 0.0157 in.)
Piston pin hole inside diameter		Standard	17.008 to 17.014 mm (0.66960 to 0.66984 in.)
Piston pin diameter		Standard	16.994 to 17.000 mm (0.66905 to 0.66929 in.)
Piston pin length		Standard	50.8 to 51.2 mm (2.00 to 2.02 in.)
Connecting rod small end diameter		Standard	16.96 to 16.976 mm (0.66772 to 0.66835 in.)
Connecting rod big end diameter		Standard	45.000 to 45.016 mm (1.77165 to 1.77228 in.)
Connecting rod length		Standard	145.575 to 145.625 mm (5.73129 to 5.73326 in.)
Crankshaft runout		Maximum	0.007 mm (0.000276 in.)
Crankshaft main journal diameter		Standard	41.984 to 42.000 mm (1.65291 to 1.65354 in.)
Crank pin diameter		Standard	41.984 to 42.000 mm (1.65291 to 1.65354 in.)
Inner diameter of the cylinder block sub-assembly and crankshaft bearing cap		Standard	45.600 to 45.619 mm (1.79527 to 1.79602 in.)
Standard crankshaft bearing thickness		- / Black	1.798 mm (0.0708 in.)
Standard No. 2 crankshaft bearing thickness		Brown	1.786 mm (0.0703 in.)
		Blue	1.794 mm (0.0706 in.)
		Green	1.802 mm (0.0709 in.)
		Yellow	1.810 mm (0.0713 in.)
Standard connecting rod bearing thickness (Upper)		-	1.492 to 1.498 mm (0.0587 to 0.0590 in.)
Standard connecting rod bearing thickness (Lower)		Brown	1.479 to 1.485 mm (0.0582 to 0.0585 in.)
		Blue	1.486 to 1.492 mm (0.0585 to 0.0587 in.)
		Green	1.493 to 1.499 mm (0.0588 to 0.0590 in.)
		Yellow	1.500 to 1.506 mm (0.0591 to 0.0593 in.)
Ring pin for cylinder block sub-assembly	Protrusion height	Pin A	5.5 to 6.5 mm (0.217 to 0.256 in.)
Straight pin for cylinder block sub-assembly	Protrusion height	Pin A	9.75 to 10.75 mm (0.384 to 0.423 in.)
Straight pin for cylinder block sub-assembly	Protrusion height	Pin B	7.5 to 8.5 mm (0.295 to 0.335 in.)