Rozdział 2 - Silnik, sprzęgło i skrzynia biegów.pdf

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2-1

Chapter 2

Engine, clutch and transmission

Contents

Alternator - removal and installation ............... .see Chapter 9

Cam chains - removal and installation ....................... 9

Cam chain tensioners and guide blades - removal, inspection and

installation ........................................... 10

Camshafts and rockers - removal, inspection and installation ..... 8

Clutch - removal, inspection and installation .................. 17

Clutch cable - replacement ................................ 18

Clutch check ................................. .see Chapter 1

Connecting rods - removal, inspection and installation .......... 29

Crankcase - inspection and servicing ........................ 22

Crankcase - separation and reassembly ...................... 21

Crankshaft and main bearings - removal, inspection and installation .. 28

Cylinder blocks - removal, inspection and installation ........... 14

Cylinder compression check ......................see Reference

Cylinder heads - removal and installation ..................... 11

Cylinder head and valves - disassembly, inspection

and reassembly ....................................... 13

Engine - removal and installation ........................... 5

Engine disassembly and reassembly - general information ....... 6

Gearchange mechanism - removal, inspection and installation .... 19

General information ...................................... 1

Idle speed check .............................. .see Chapter 1

Ignition pulse generator - removal and installation .... .see Chapter 5

Initial start-up after overhaul ............................... 30

Main and connecting rod bearings - general note .............. 27

Major engine repair - general note .......................... 4

Oil and filter change ............................ .see Chapter 1

Oil level check .......................see Daily (pre-ride) checks

Oil pressure switch - check, removal and installation .. .see Chapter 9

Oil pump and pressure relief valve - removal, inspection,

installation and pressure check ........................... 23

Operations possible with the engine in the frame ............... 2

Operations requiring engine removal.......................... 3

Pistons - removal, inspection and installation .................. 15

Piston rings - inspection and installation ...................... 16

Recommended running-in procedure ........................ 31

Selector drum and forks - removal, inspection and installation .... 26

Spark plug checks ..............................see Chapter 1

Starter clutch and idle/reduction gear assembly -

removal, inspection and installation ....................... 20

Starter motor - removal and installation .............see Chapter 9

Transmission shafts - disassembly, inspection and reassembly ... 25

Transmission shafts - removal and installation ................. 24

Valve clearance check .......................... .see Chapter 1

Valve covers - removal and installation ....................... 7

Valves/valve seats/valve guides - servicing ................... 12

Degrees of difficulty

Easy, suitable for

|k

Fairly easy, suitable |k

for beginner with

Fairly difficult, |k

suitable for competent ^

DIY mechanic

Difficult, suitable for -^

experienced DIY

Very difficult, ^k

suitable for expert DIY ^

or professional

novice with little

^

^

^

experience

^

some experience

2S

JjS

mechanic

^S

^

Specifications

General

Capacity

600 cc engine (J, K, M models) ............................. 583 cc

650 cc engine (P, S, T models) .............................. 647 cc

Bore

600 cc engine (J, K, M models) ............................. 75.0 mm

650 cc engine (P, S, T models) .............................. 79.0 mm

Stroke ................................................. 66.0 mm

Compression ratio ......................................... 9.2 to 1

Cylinder compression ....................................... 192 ± 28 psi (13.25 ± 1.9 Bar)

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2»2 Engine, clutch and transmission

Camshafts, rockers and cam chain

Cam chain tensioner projection (max) .......................... 6 mm

Camshaft

Intake lobe height

Standard ............................................. 38.189 mm

Service limit ........................................... 38.17 mm

Exhaust lobe height

Standard ............................................. 38.123 mm

Service limit ........................................... 38.19 mm

Journal diameter

Standard ............................................. 21.959 to 21.980 mm

Service limit ........................................... 21.95 mm

Camshaft bearing oil clearance

Standard ............................................... 0.040 to 0.093 mm

Service limit............................................. 0.11 mm

Camshaft runout

Standard ............................................... 0.03 mm

Service limit............................................. 0.05 mm

Rocker shaft diameter

Standard ............................................... 11.966 to 11.984 mm

Service limit............................................. 11.96 mm

Rocker arm internal diameter

Standard ............................................... 12.000 to 12.018 mm

Service limit............................................. 12.03 mm

Cylinder head

Warpage (max) ............................................ 0.10 mm

Valves, guides and springs

Intake valve

Stem diameter

Standard ............................................. 5.475 to 5.490 mm

Service limit ........................................... 5.47 mm

Guide bore diameter

Standard ............................................. 5.500 to 5.512 mm

Service limit ........................................... 5.53 mm

Stem-to-guide clearance

Standard ............................................. 0.010 to 0.037 mm

Service limit........................................... 0.07 mm

Seat width

Standard ............................................. 0.9 to 1.1 mm

Service limit ........................................... 1.5 mm

Spring free lengths

Inner spring ........................................... 36.47 mm

Outer spring .......................................... 40.58 mm

Guide projection height ................................... 19.4 to 19.6 mm

Exhaust valve

Stem diameter

Standard ............................................. 6.555 to 6.570 mm

Service limit ........................................... 6.55 mm

Guide bore diameter

Standard ............................................. 6.600 to 6.615 mm

Service limit ........................................... 6.66 mm

Stem-to-guide clearance

Standard ............................................. 0.030 to 0.060 mm

Service limit ........................................... 0.11 mm

Seat width

Standard ............................................. 0.9 to 1.1 mm

Service limit ........................................... 1.5 mm

Spring free lengths

Inner spring ........................................... 37.51 mm

Outer spring .......................................... 41.25 mm

Guide projection height ................................... 17.9 to 18.1 mm

Valve clearances ........................................... see Chapter 1

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Engine, clutch and transmission 2»3

Cylinder block

Bore diameter

600 cc engine

Standard ............................................. 75.00 to 75.015 mm

Wear limit ............................................ 75.10 mm

650 cc engine

Standard ............................................. 79.00 to 79.015 mm

Wear limit ............................................ 79.05 mm

Taper (max) ............................................... 0.06 mm

Ovality (max) .............................................. 0.06 mm

Warpage (max) ............................................ 0.10 mm

Pistons

Piston diameter (measured 10.0 mm up from skirt, at 90° to piston pin axis)

600 cc engine

Standard ............................................. 74.965 to 74.990 mm

Service limit ........................................... 74.90 mm

650 cc engine

Standard ............................................. 78.970 to 78.990 mm

Service limit ........................................... 78.92 mm

• 1 st oversize ............................................... +0.25 mm

2nd oversize .............................................. +0.50 mm

Piston-to-bore clearance

Standard ............................................... 0.010 to 0.035 mm

Service limit............................................. 0.13 mm

Piston pin diameter

600 cc engine

Standard ............................................. 17.994 to 18.000 mm

Service limit ........................................... 17.98 mm

650 cc engine

Standard ............................................. 19.994 to 20.000 mm

Service limit ........................................... 19.98 mm

Piston pin bore

600 cc engine

Standard ............................................. 18.002 to 18.008 mm

Service limit ........................................... 18.05 mm

650 cc engine

Standard ............................................. 20.002 to 20.008 mm

service limit ........................................... 20.02 mm

Piston pin-to-bore clearance

Standard ............................................... 0.002 to 0.014 mm

Service limit............................................. 0.034 mm

Connecting rod small-end internal diameter

600 cc engine

Standard ............................................. 18.016 to 18.034 mm

Service limit........................................... 18.07 mm

650 cc engine

Standard ............................................. 20.016 to 20.034 mm

Service limit ........................................... 20.04 mm

Piston pin-to-connecting rod small-end clearance

Standard ............................................... 0.016 to 0.040 mm

Service limit............................................. 0.060 mm

Piston rings

Ring-to-groove clearance

Top ring

Standard ............................................. 0.025 to 0.055 mm

Service limit........................................... 0.11 mm

2nd ring

Standard ............................................. 0.015 to 0.045 mm

Service limit........................................... 0.10 mm

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2*4 Engine, clutch and transmission

Piston rings (continued)

End gap (installed)

Top ring

Standard ............................................. 0.20 to 0.35 mm

Service limit ........................................... 0.65 mm

2nd ring

Standard ............................................. 0.35 to 0.50 mm

Service limit ........................................... 0.65 mm

Oil ring

Standard ............................................. 0.2 to 0.8 mm

Service limit ........................................... 0.95 mm

Connecting rods

Side clearance

Standard ............................................... 0.05 to 0.20 mm

Service limit............................................. 0.3 mm

Bearing oil clearance

Standard ............................................... 0.028 to 0.052 mm

Service limit............................................. 0.08 mm

Big-end internal diameter

Size code 1 .............................................

39.000 to 39.006 mm

Size code 2 .............................................

39.006 to 39.012 mm

Crankpin diameter

Size code A ............................................. 35.994 to 36.000 mm

Size code B ............................................. 35.988 to 35.994 mm

For connecting rod small-end specifications see under "Pistons".

Crankshaft and bearings

Main bearing oil clearance

Standard ............................................... 0.025 to 0.041 mm

Service limit............................................. 0.06 mm

Runout (max) ............................................. 0.05 mm

Clutch

Friction plate (see Section 17 for identification)

Type A

Quantity.............................................. 1

Thickness ............................................ 2.92 to 3.08 mm

Service limit ........................................... 2.6 mm

Type B

Quantity.............................................. 6

Thickness ............................................ 2.62 to 2.78 mm

Service limit ........................................... 2.3 mm

TypeC

Quantity.............................................. 1

Thickness ............................................ 2.62 to 2.78 mm

Service limit ........................................... 2.3 mm

Plain plate

Quantity................................................ 7

Warpage (max) .......................................... 0.3 mm

Springs

Free length ............................................. 44.4 mm

Service limit............................................. 42.8 mm

Mainshaft diameter at clutch housing guide

Standard ............................................... 21.967 to 21.980 mm

Service limit............................................. 21.92 mm

Clutch housing guide

Internal diameter

Standard ............................................. 21.991 to 22.016 mm

Service limit ........................................... 22.09 mm

External diameter

Standard ............................................. 31.959 to 31.975 mm

Service limit ........................................... 31.92 mm

Clutch housing internal diameter

Standard ............................................... 32.000 to 32.025 mm

Service limit............................................. 32.10 mm

Oil pump drive sprocket internal diameter

Standard ............................................... 32.000 to 32.025 mm

Service limit............................................. 32.10 mm

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Engine, clutch and transmission 2»5

Starter clutch

Starter driven gear hub external diameter

Standard ............................................... 57.749 to 57.768 mm

Service limit............................................. 57.60 mm

Transmission

Type

Gearbox ............................................... 5 speed, constant mesh

Final drive .............................................. Shaft

Gear ratios (No. of teeth)

Primary reduction

600 cc engine ......................................... 1.888 to 1 (68/36T)

650 cc engine ......................................... 1.763 to 1 (67/38T)

Secondary reduction ...................................... 0.882 to 1 (30/34T)

Tertiary reduction ........................................ 1.058 to 1 (18/17T)

Final drive .............................................. 2.909 to 1 (32/11T)

1st gear ................................................ 2.571 to 1 (36/14T)

2nd gear ............................................... 1.882 to 1 (32/177)

3rd gear................................................ 1.500 to 1 (30/20T)

4th gear................................................ 1.240 to 1 (31/257)

5th gear ................................................ 1.074 to 1 (29/27T)

Gear ID

Mainshaft 4th and 5th gears

Standard ............................................. 28.000 to 28.021 mm

Service limit ........................................... 28.03 mm

Countershaft 1 st gear

Standard ............................................. 24.000 to 24.021 mm

Service limit........................................... 24.03 mm

Countershaft 2nd and 3rd gears

Standard ............................................. 28.000 to 28.021 mm

Service limit........................................... 28.03 mm

Output drive shaft driven gear

Standard ............................................. 24.000 to 24.021 mm

Service limit........................................... 24.10 mm

Gear bushing OD

Mainshaft 4th and 5th gears

Standard ............................................. 27.959 to 27.980 mm

Service limit ........................................... 27.95 mm

Countershaft 1st gear

Standard ............................................. 23.959 to 23.980 mm

Service limit........................................... 23.95 mm

Countershaft 2nd and 3rd gears

Standard ............................................. 27.959 to 27.980 mm

Service limit........................................... 27.95 mm

Output drive shaft driven gear

Standard ............................................. 23.959 to 23.980 mm

Service limit ........................................... 23.70 mm

Gear bushing ID

Mainshaft 4th gear

Standard ............................................. 25.000 to 25.021 mm

Service limit........................................... 25.03 mm

Countershaft 1 st gear

Standard ............................................. 20.016 to 20.037 mm

Service limit ........................................... 20.05 mm

Countershaft 2nd and 3rd gears

Standard ............................................. 25.000 to 25.021 mm

Service limit........................................... 25.03 mm

Output drive shaft driven gear

Standard ............................................. 20.020 to 20.041 mm

Service limit ........................................... 20.10 mm

Gear-to-bushing clearance

Mainshaft 4th and 5th gear

Standard ............................................. 0.020 to 0.062 mm

Service limit........................................... 0.08 mm

Countershaft 1st, 2nd and 3rd gear

Standard ............................................. 0.020 to 0.062 mm

Service limit ........................................... 0.08 mm

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