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HONDA
EPSOOO-EPSSOOS
4.
MAINTENANCE STANDARDS
• ENGINE
EP5000
EP6500S
Part
Item
Standard
Service
limit
Standard
Service
limit
Engine
Maximum
speed
50
Hz
3,150
±
150
mlrr '
(rpm)
--
3,150
±
150
rnlrr
'
(rpm)
60 Hz
3,750
±
150
rnirr
'
(rpm)
--
3,750
±
150
rmrr ' (rpm)
--
Cylinder
compression
6.0
-
8.5
kg/cm'
6.0 - 8.5
kg/cm'
(85
-
121
psi)
--
(85 -121
psi)
--
at 600
min-
1
(rpm)
at 600
rmrr" (rpm)
Cylinder
Sleeve
1.0.
82.00 mm (3.228 in)
82.17 mm (3.235 in)
88.00 mm (3.465
in)
88.17
mm (3.471
in)
Cylinder
head
Warpage
--
0.10 mm (0.004
in)
--
0.10
mm
(0.004
in)
Piston
Skirt
0.0.
81.985 mm (3.2277
in)
81.85 mm (3.222
in)
87.985 mm (3.4640
in)
87.85 mm (3.459
in)
Piston-to-cylinder
0.015 - 0.052 mm
0.12 mm
0.015 - 0.052 mm
0.12mm
clearance
(0.0006 - 0.0020 in)
(0.005
in)
(0.0006 - 0.0020
in)
(0.005
in)
Piston pin bore
1.0.
20.002 mm (0.7875 in)
20.042 mm (0.7891 in)
20.002 mm (0.7875
in)
20.042 mm (0.7891
in)
Pin
0.0.
20.00 mm (0.787 in)
19.95 mm (0.785
in)
20.00 mm (0.787
in)
19.95 mm (0.785
in)
Piston-to-piston
pin
0.002 - 0.014 mm
0.08 mm
0.002 - 0.014 mm
0.08
mm
bore
clearance
(0.0001 - 0.0006 in)
(0.003
in)
(0.0001 - 0.0006 in)
(0.003
in)
Piston rings
Ring side
clearance:
0.030 - 0.060 mm
0.15mm
0.030 - 0.060 mm
0.15 mm
Top/second
(0.0012 - 0.0024 in)
(0.006
in)
(0.0012 - 0.0024
in)
(0.006
in)
Ring end
gap:
0.2-0.4mm
1.0mm
0.2-0.4mm
1.0mm
Top/second
(0.01 - 0.02 in)
(0.04
in)
(0.01 - 0.02 in)
(0.04
in)
Oil
0.2 -0.7
mm
1.0mm
0.2-0.7
mm
1.0mm
(0.01 :...0.03 in)
(0.04
in)
(0.01 - 0.03 in)
(0.04
in)
Ring
width:
Top/second
2.0 mm (0.08 in)
1.75 mm (0.069 in)
2.0 mm (0.08
in)
1.75 mm (0.069
in)
Connecting
Small
end
1.0.
20.005 mm (0.7876 in)
20.07 mm (0.790
in)
20.005 mm (0.7876
in)
20.07 mm (0.790
in)
rod
Big end
1.0.
36.025 mm (1.4183
in)
36.07 mm (1.420
in)
36.025 mm (1.4183
in)
36.07 mm
(1.420
in)
Big end oil clearance
0.040 - 0.066 mm
0.12 mm
0.040 - 0.066 mm
0.12 mm
(0.0016 - 0.0026 in)
(0.005
in)
(0.0016 - 0.0026
in)
(0.005
in)
Big end side clearance
0.1-0.7
mm
1.0mm
0.1-0.7mm
1.0mm
(0.004
-
0.028 in)
(0.04 in)
(0.004 - 0.028 in)
(0.04 in)
Crankshaft
Crankshaft
0.0.
35.985 mm (1.4167 in)
35.93 mm (1.415
in)
35.985 mm (1.4167
in)
35.93 mm (1.415
in)
Valves
Valve clearance
IN
0.15
±
0.02 mm
--
0.15
±
0.02 mm
--
(0.006
±
0.001 in)
(0.006
±
0.001
in)
EX
0.20 ± 0.02 mm
--
0.20
±
0.02 mm
--
(0.008
±
0.001
in)
(0.008
±
0.001
in)
Stem
0.0.
IN
6.59 mm (0.259 in)
6.44 mm (0.254 in)
6.59 mm (0.259 in)
6.44 mm (0.254
in)
EX
6.55 mm
(0.258
in)
6.40 mm (0.252 in)
6.55 mm (0.258 in)
6.40 mm (0.252
in)
Guide
1.0.
IN/EX
6.60 mm (0.260 in)
6.66 mm (0.262 in)
6.60 mm (0.260 in)
6.66 mm (0.262
in)
Stem
clearance
IN
0.010 - 0.040 mm
0.11 mm
0.010 - 0.040 mm
0.11 mm
(0.0004 - 0.0016
in)
(0.004 in)
(0.0004 - 0.0016
in)
(0.004
in)
EX
0.050 - 0.080 mm
0.13 mm
0.050 - 0.080 mm
0.13 mm
(0.0020 - 0.0031
in)
(0.005 in)
(0.0020 - 0.0031
in)
(0.005
in)
Seat width
1.1 mm (0.04
in)
2.0 mm (0.08
in)
1.1 mm (0.04
in)
2.0 mm
(0.08
in)
Spring
free
length
39.0 mm (1.54
in)
37.5 mm (1.48 in)
39.0 mm (1.54
in)
37.5 mm (1.48
in)
Camshaft
Cam height
IN
31.85 - 32.25 mm
31.10 mm
32.40 - 32.80 mm
32.25 mm
(1.254 - 1.270
in)
(1.224 in)
(1.276 - 1.291
in)
(1.270
in)
EX
31.57 - 31.97 mm
30.80 mm
31.89 - 32.29 mm
31.75 mm
(1.243 - 1.259
in)
(1.213 in)
(1.256 - 1.271 in)
(1.250
in)
Camshaft
0.0.
15.984 mm (0.6293
in)
15.92 mm (0.627
in)
15.984 mm (0.6293
in)
15.92 mm (0.627
in)
Crankcase
Camshaft
holder
1.0.
16.0 mm (0.63
in)
16.05 mm (0.632 in)
16.0 mm (0.63
in)
16.05 mm (0.632
in)
cover
Carburetor
Main jet
#98
--
# 102
--
Float height
13.2 mm (0.52
in)
--
13.2 mm (0.52
in)
--
Pilot screw opening
2-5/8 turns
out
--
2-1/4
turns out
--
Spark
plug
Gap
0.7-0.8
mm
0.7-0.8
mm
--
(0.028 -
0.031
in)
--
(0.028
-
0.031
in)
Spark plug cap
Resistance
7.5
-
12.5
kO
--
7.5
-
12.5
kO
--
Ignition
coil
Resistance
Primary
coil
0.8-1.00
--
0.8-1.0
!2
--
Secondary
coil
5.9
-
7.1
k{l
--
5.9-7.1
k!2
--
Air
gap
(at
flywheel)
0.4±
0.2 mm
0.4± 0.2
mm
(0.016
±
0.008 in)
--
(0.016
±
0.008
in)
--
Starter motor
Brush length
--
--
7.0 mm
(0.28
in)
3.5 mm (0.14
in)
Mica depth
--
--
1.0
mm
(0.04
in)
0.2 mm (0.01
in)
2-3
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