Crankcase/Transmission Specifications; Crankshaft Piston/Cylinder Specifications - Honda INTERCEPTOR 2002 Service Manual

GENERAL INFORMATION
CRANKCASE/TRANSMISSION SPECIFICATIONS
Unit: mm (in)
ITEM
STANDARD SERVICE LIMIT
Transmission
Gear I.D.
~M6 28.000- 28.021 ( 1.1024 - 1.1032) 28.04 (1.104)
C1 26.007- 26.028 (1.0239- 1.0247)
26.04 (1.025)
C2
31.000- 31.025 ( 1.2205 - 1.2215)
31.04 (1.222)
C3, C4 31.000 -31.025 (1.2205 - 1.2215)
31.04 (1.222)
I
Gear busing O.D. M5, M6 27.959 -27.980 (1.1007- 1.1016)
27.94 ( 1.100)
C2 30.970- 30.995 (1.2193- 1.2203)
30.95 (1.219)
C3,C4 30.950- 30.975 (1.2185 - 1.2195)
- 1
30.93 (1.218)
Gear-to-bushing M5, M6 0.020-0.062 (0.0008- 0.0024)
-
clearance
•
C2 0.005-0.055 (0.0002- 0.0022)
I
- __,
-
I
0.025- 0.075 (0.0010 - 0.0030)
--
t_9.
C4
-
I
Gear bushing J.D.
I
M5 24.985- 25.006 (0.9837 - 0.9845)
25.03 (0.985)
I
C2
28.000- 28.021 (1. 1024- 1.1032)
28.04 (1.104)
Mainshaft O.D. at M5
24.959- 24.980 (0.9826- 0.9835) 24.95 (0.982)
Countershaft O.D. at C2 27.967 - 27.980 ( 1.1011 - 1.1016)
27.96 ( 1.101)
Bushing-to-shaft M5 0.005 -0.047 (0.0002- 0.0019)
-
clearance
C2 0.020- 0.054 (0.0008- 0.0021)
-
Shift fork,
I
-
Fork J.D.
--
14.000 - 14.021 (0.5512- 0.5520)
14.03 (0.552)
fork shaft
Claw thickness
6.43 - 6.50 (0.253- 0.256)
6.40 (0.252)
Shift fork shaft O.D.
I
13.973-13.984 (0.5501 - 0.5506)
13.965 (0.5498)
CRANKSHAFT /PISTON/CYLINDER SPECIFICATIONS
r -
ITEM STANDARD
Unit: mm (in)
SERVICE LIMIT
Crankshaft
·-
Cylinder
Connecting rod sid-e clearance 0. 10-0.30 (0.004- 0.012)
Runout
-
Main journal bearing oil clearance 0.019- 0.037 (0.0007- 0.0015)
1.0, 72.000- 72.015 (2.8346 - 2.8352)
- -
0.40 (0.016)
0.05 (0.002)
0.05 (0.002)
72.10 (2.839)
Out of round 0.10 (0.004)
Taper 0.10 (0.004)
Warpage
=-=,....,...-,.....,....--.......-~ ~~~~~~~--~--+-~ 0-~ 10 . :.....:..:( 0 ,-:.. .00_ 4) ;..,.------'
>--; P ~is - :- t - o n-,- p..,...is 7 to-n--.P;:;-:-i-:st..!.o_n.:;.O'".O:o-.-a-:-t
-:-;;-18 mm (0.7 in) from 71.965-71.985 (2.8333- 2.8340) 71.90 (2.831)
rings bottom
Piston pin bore 1.0. 17.002- 17.008 (0.6694 - 0.6696) 17.02 (0.670)
~=P~is~t~on~p~in~O~.~O~. ~--_-_- _ - _ - _ - _ - _ - _ - _ +~- - ~1 ~ 6~.9~9~4=-~1~7~.~ 0~ 0 0~~~-6~6~9~1~ -~0~.6~6~93~)=====~~-1~6~.9~8~(0~.~66~9~)-~
i'<"P i ,..., st,.- o.._n_-t;.:.o...!-p:...:.is~ t..:;..on ~p~ i n, c-- le:,;a,.;..; ra ~ n...::. c~ e --+-~0~. 0~0~2 - 0.014 (0.0~0~0~ 1 -=-~0;.;.0:...:0~0=-6)'-----+-=-0~.0...:.,4 7 (0 7 .~00~ 2 :..:..)
- - - l
Piston ring end li:-o:..!:p_..,..----1-0.20- 0.30 (0.008 - 0.012)
0::;.5:._c(c;0~.0.;.2);._
_
___..j
gap Second 0.30-0.45 (0.012- 0.018) 0.6 (0.02)
Oil 0.20- 0.70 (0.008 - 0.028) 0.9 (0.04)
(side rail)
~=--~-~-~-=
Piston ring-to-ring Top 0.030-0.065 (0.0012- 0.0026) 0. 11 (0.004)
groove clearance Second 0.015- 0.050 (0.0006 - 0.0020) 0. 10 (0.004)
Cylinder-to-piston c
7
1e-a-ra_n_c_e _ _ _
__..__;;;~:...:....::.---~0.~015-
0.050 (0.0006 - 0.0020) 0.10 (0.004)
~---cC;,..o :...:.n.;_n...::.e~ct;:-i
n_,.g:....:. r. . : : : . . o . . : ; . . d
..:::..sm~a;.:.. ll ...::. en : ...:. d ::...:.;.: I.D~.-:----------___:1.:..:7...:.:01:.::.6
- 17.034 (0 .6699 - 0.6706) 17.04 (0.671)
Connecting rod-to-piston pin clearance 0.016- 0.040 (0.0006 - 0.0016) 0.06 (0.002)
·~~..!.------------~~
Crankpin bearing oil _ c _ l e_a_ra_n_ce _ __ _ _ __ _ __..__:_0.:...:.0..:::..30 .:.._ - 0.052 (0.0012 - 0.0020) 0.08 (0.003)
1-8