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SERVICE STANDARDSIREPAIR LlMITS/MAINTENANCE
Part IIaIIIe
Check/lllSllect
Standard Value/Maintenance
Repair Limit
Connecting Rod
1.
Inner diameter of the small end.
1. 16.01mm (0.630in)
1.
16.04mm (0.631 in) or more.
2.
Oil clearance of the big end.
2. 0.Q15 - 0.041mm (0.0006 - 0.0016in)
2. 0.060mm (0.002in) or more.
3. Side clearance of the big end.
3.0.1 - 0.25mm (0.004 - 0.01 in)
3. 0.6mm (0.024in) or more.
Magneto
• Inition liming
BTDC 5' - 5' (electric ignition advance)
• Spark performance
10mm (0.4in) or more/500 rpm
(measured by genuine spark tester.
• Spark plug
NGK DCPR6E
• Spark gap
0.8 - 0.9mm (0.032 - 0.035in)
1.2mm 9 0.0047in) or more
• Alternator output
12V. 130W (5000 rpm)
• Resistance of coils
Between white wire and yellow wire
0.27 - 0.410
Between red-white wire and
black wire
148 - 2220
Between black-red wire and blue wire
12.5 - 18.80
Between yellow-red wire and
yellow -red wire
1.40 - 2.100
• ESG for high speed
Restricting at 6250 rpm
• ESG for low speed
Reducing at 2000rpm
Ignition Coil
• Resistance of primary coil
between black wire and orange wire
0.26 - 0.350
• Resistance of secondary coil
between high tension cord and core
6800 - 102000
Battery
Output
12V -70AH to 12V -100AH
12VO.6KW
Clutch
Over-running clutch
1)
Brush length
1) 12.5mm (0.49in)
1) 9.5mm (0.37in) or less
2)
Commutator under-cut
2) 0.5-0.8mm (0.02-0.03in)
2) 0.2mm (0.008in) or less
3)
Commutator diameter
3)30mm (1.18in)
3)29 mm (1.14in) or less
Fuse
Capacity
120A
Thermostat
Operation of thermostat
• Start to open: 60'C
±
1.5'C
If the valve opens at room temperature •
(140
±
3'F)
replace the thermostat.
• Temperature at which valve opens
While immersing the thermostat in water,
full: 75'C (167'F)
raise the water temperature and check the
temperature at which the valve opens.
Pump Impeller
Worn-out, crack
Replace
Pump Case liner Worn-out
Replace
Guide Plate
Worn-out
Replace
Intake Valve
1)
Valve Clearance
IN: 0.13 - 0.17mm (0.005 - 0.007in)
Exhaust Valve
EX: 0.18 - 0.22mm (0.007 - 0.008in)
2)
Outer diameter of valve stem
IN: 0.13 - 0.17mm (0.005 - 0.007in)
5.46mm (0.215in) or less
EX: 0.18 - 0.22mm (0.007 - 0.008in)
5.44mm (0.214in) or less
3) Inner diameter of valve guide
IN: 0.13 - 0.17mm (0.005 - 0.007in)
5.55mm (0.218in) or more
EX: 0.18 - 0.22mm (0.007 - 0.008in)
5.57mm (0.219in) or more
4) Clearance to valve stem
IN: 0.13 - 0.17mm (0.005 - 0.007in)
0.07mm (0.0028in) or more
EX: 0.18 - 0.22mm (0.007 - 0.008in)
0.10",m (0.004in) or more
5) Contact width of valve seat
IN: 0.13 - 0.17mm (0.005 - 0.007in)
2.0mm (0.079in) or more
EX: 0.18 - 0.22mm (0.007 - 0.008in)
2.0mm (0.079in) or more
Valve Spring
Free length
35mm (1.38in)
33.5mm (1.319in) or less
Camshaft
1) Height of cam (both IN and EX)
1) 23.90mm (0.94in)
1) 23.75mm (0.935in) or less
2)
Outer diameter of bearing
2) Pulley side: 17.98mm (0.0708in)
2) 17.95mm (0.707in) or less
Oil pump side:: 15.97mm(0.629in)
15.95mm (0.628in) or less
3) Clearance of holder (bearing)
3) 0.02 - 0.05mm (0.0008 - 0.0020in)
3) 0.09mm (0.0035in) or more
Rocker Arm
1) Inner diameter
1) 13.01mm (0.512in)
1) 13.05mm (0.514in) or less
and Shaft
2)
Outer diameter
2) 12.99mm (0.511in)
2) 12.94mm (0.509in) or less
3) Shaft Clearance
3) 0.006 - 0.035mm (0.00024 -0.00138in)
3) 0.6 mm (0.0024in) or less
Timing Belt
Tension and appearance
Wear, crack or lengthen-replace
Engines & Generators
13
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