SERVICE DATA Date: August 1, 2007
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1 SERVICE DATA Date: August 1, 2007 Model: LT-A450XK8 VALVE + VALVE GUIDE Valve diam IN. (1.20) EX (1.06) Tappet clearance (when cold) IN. ( ) EX ( ) Valve guide to valve stem clearance Valve guide I.D. Valve stem O.D. Valve stem deflection Valve stem runout Valve head thickness Valve seat width Valve head radial runout Valve spring free length Valve spring tension IN. EX. IN. & EX. IN. EX ( ) ( ) ( ) ( ) ( ) IN. & EX. IN. & EX. IN. & EX. IN. & EX ( ) IN. & EX. IN. & EX. IN. & EX N ( kgf, lbs) at length 31.5 mm (1.24 in) 0.35 (0.014) 0.05 (0.002) 0.5 (0.02) 0.03 (0.001) 38.8 (1.52) Model: LT-A450XK8 1/10 P-17, 24, 28, 33
2 CAMSHAFT + CYLINDER HEAD Cam height IN. EX. CYLINDER + PISTON + PISTON RING ( ) ( ) (1.3051) (1.3059) Camshaft journal oil clearance ( ) (0.0059) ( ) Camshaft journal holder I.D ( ) ( ) Camshaft journal O.D ( ) ( ) Camshaft runout 0.10 (0.004) Rocker arm I.D IN. & EX. ( ) Rocker arm shaft O.D IN. & EX. ( ) Cylinder head distortion 0.05 (0.002) Cylinder head cover distortion 0.05 (0.002) Compression pressure (Automatic-decomp. actuated) Approx kpa (10.0 kgf/cm², 142 psi) Piston-to-cylinder clearance ( ) Cylinder bore ( ) Piston diam ( ) Measure at 15 mm (0.6 in) from the skirt end. Cylinder distortion Piston ring free end gap 1st R Approx 9.9 (0.38) 2nd R Approx 9.7 (0.38) (0.0047) Nicks or Scratches (3.3023) 0.05 (0.102) 7.9 (0.31) 7.7 (0.30) Model: LT-A450XK8 2/10 P-17, 24, 28, 33
3 Piston ring end gap st R ( ) (0.020) Piston ring to groove clearance CONROD + CRANKSHAFT OIL PUMP 2nd R ( ) 1st 2nd Piston ring groove width st ( ) nd ( ) Oil ( ) Piston ring thickness st ( ) nd ( ) Piston pin bore I.D ( ) Piston pin O.D ( ) 0.50 (0.020) (0.0071) (0.0059) (0.7885) (0.7866) Conrod small end I.D ( ) (0.7889) Conrod deflection 3.0 (0.12) Conrod big end side clearance ( ) Conrod big end width ( ) Crank web to web width ( ) Crankshaft runout 1.0 (0.039) 0.08 (0.003) Oil pressure (at 60 C, 140 F) 100 kpa (1.0 kgf/cm², 14.2 psi) at r/min Model: LT-A450XK8 3/10 P-17, 24, 28, 33
4 CLUTCH DRIVE TRAIN Clutch wheel I.D ( ) Clutch shoe (5.53) No groove at any part Clutch engagement r/min r/min. Clutch lock-up r/min r/min. Except ratio Automatic transmission ratio Variable change ( ) Secondary reduction ratio (41/19 19/15) Final reduction ratio Front (36/10) Rear (36/10) Transfer gear ratio Low (41/16) High (31/25) Reverse (32/16) Drive belt width 31.1 (1.22) Movable driven face spring free length (8.46) Shift fork to groove clearance ( ) Shift fork groove width Shift fork thickness Reverse High Reverse High Front/rear output shaft bevel gear backlash Front drive (differential) gear backlash ( ) ( ) ( ) ( ) ( ) ( ) 30.1 (1.18) (8.04) 0.50 (0.020) Final gear backlash ( ) Front differential gear oil type Hypoid gear oil SAE #90, API grade GL-5 or SAE 75 W-90 Final gear oil type Mobil fluid 424 (or equivalent gear oil) Front differential gear oil capacity 500 ml (16.9/17.6 US/lmp oz) Final gear oil capacity 770 ml (26.0/27.1 US/lmp oz) Model: LT-A450XK8 4/10 P-17, 24, 28, 33
5 THERMOSTAT + RADIATOR + FAN + COOLANT ITEM STANDARD/SPECIFICATION NOTE Thermostat valve opening temperature Approx. 82 C (180 F) Thermostat valve lift 8 mm (0.315 in) and over at 95 C (203 F) Radiator cap valve opening pressure Cooling fan thermo-switch operating temperature Engine coolant type Engine coolant capacity kpa ( kgf/cm², psi) OFF ON Approx. 93 C (199 F) ON OFF Approx. 87 C (189 F) Use an antifreeze/coolant compatible with aluminum radiator, mixed with distilled water only, at the ratio of 50: ml Reservoir (0.26/0.22 US/lmp qt) ml Engine ( US/lmp qt) INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR ITEM SPECIFICATION NOTE Injector resistance Ω at 20 C (68 F) Fuel pump discharge amount 55.5 ml (1.88/1.95 US/lmp oz) and more/10 sec. Fuel pressure regulator operating set pressure Approx. 294 kpa (3.0 kgf/cm², 41 psi) Model: LT-A450XK8 5/10 P-17, 24, 28, 33
6 FI SENSORS ITEM SPECIFICATION NOTE CKP sensor resistance Ω CKP sensor peak voltage 65 V and more When cranking IAP sensor input voltage V IAP sensor output voltage V at idle speed TP sensor input voltage V TP sensor resistance Closed Approx kω Opened Approx kω TP sensor output voltage Closed V Opened V ECT sensor input voltage V ECT sensor resistance 20 C (68 F) Approx kω 40 C (104 F) Approx kω 80 C (176 F) Approx kω 100 C (182 F) Approx kω IAT sensor input voltage V IAT sensor output voltage Approx V at 20 C (68 F) IAT sensor resistance 20 C (68 F) kω 40 C (104 F) kω TO sensor resistance kω TO sensor voltage Normal V Leaning V When leaning 65 Injector voltage Battery voltage Ignition coil primary peak voltage 80 V and more When cranking Model: LT-A450XK8 6/10 P-17, 24, 28, 33
7 THROTTLE BODY ITEM Bore size I.D. No. Idle r/min. Throttle cable play STANDARD/SPECIFICATION 35 mm 11H ± 100 r/min. 3 5 mm ( in) ELECTRICAL ITEM STANDARD/SPECIFICATION NOTE Spark plug NGK: CR6E Type DENSO: U20ESR-N Gap ( ) Spark performance Over 8 (0.3) at 1 atm. Ignition coil resistance Terminal Primary Ω Ground Secondary kω Plug cap Terminal Generator coil resistance Ω Generator Max. output Approx. 375 W at r/min Generator no-load voltage (when engine is cold) 65 V (AC) and more at r/min. Regulated voltage V at r/min. Starter relay resistance 3 5 Ω Battery Type designation YTX14-BS Capacity 12 V 43.2 kc (12 Ah)/10 HR Fuse size HI 10 A Headlight LO 10 A Power source 10 A Ignition 15 A Fuel 10 A Fan 15 A Main 30 A Model: LT-A450XK8 7/10 P-17, 24, 28, 33
8 WATTAGE ITEM STANDARD/SPECIFICATION E-24, -28, -33 E-17 Headlight HI 35 2 LO 35 2 Brake light/taillight 21/5 Reversing light 21 Speedometer light LED High beam indicator light LED Neutral indicator light LED FI indicator light/engine coolant temp. indicator light LED Reverse indicator light LED Differential lock indicator light LED Unit: W BRAKE + WHEEL ITEM STANDARD/SPECIFICATION LIMIT Rear brake pedal height ( ) Rear brake pedal free travel ( ) Front brake disc thickness ( ) Front brake disc runout 3.0 (0.20) 0.30 (0.012) Front master cylinder bore ( ) Front master cylinder piston diam ( ) Front brake caliper cylinder bore ( ) Front brake caliper piston diam ( ) Rear brake lever play 6 8 ( ) Brake fluid type DOT 4 Model: LT-A450XK8 8/10 P-17, 24, 28, 33
9 Steering angle 46 (right & left) Turning radius 3.1 m (10.2 ft) Toe (with 75 kg, 165 lbs) -10 ± 4 mm (0.39 ± 0.16 in) Camber 0.64 Caster 1.6 TIRE Cold inflation tire pressure (Solo riding) SUSPENSION Front Rear 35 kpa (0.35 kgf/cm², 5.1 psi) 30 kpa (0.30 kgf/cm², 4.4 psi) Tire size Front AT , tubeless Rear AT , tubeless Tire tread depth 4.0 Front (0.16) Rear 4.0 (0.16) Front shock absorber spring adjustor 2/5 position Rear shock absorber spring adjuster 2/5 position Model: LT-A450XK8 9/10 P-17, 24, 28, 33
10 FUEL + OIL ITEM SPECIFICATION NOTE Fuel type Use only unleaded gasoline of at least 87 pump octane (R/2 + M/2) or 91 octane or higher rated by the Research Method. Gasoline containing MTBE (Methyl Tertiary E-28, 33 Butyl Ether), less than 10 % ethanol, or less than 5 % methanol with appropriate cosolvents and corrosion inhibitor is permissible. Gasoline used should be graded 91 octane or higher. The others An unleaded gasoline is recommended. Fuel tank capacity 17.5 L (4.6/3.8 US/lmp gal) Engine oil type SAE 10 W-40, API SF/SG or SH/SJ with JASO MA Engine oil capacity ml change (2.6/2.2 US/lmp qt) Filter change Overhaul ml (2.8/2.4 US/lmp qt) ml (3.4/2.8 US/lmp qt) Model: LT-A450XK8 10/10 P-17, 24, 28, 33
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