SERVICE DATA Date: August 1, 2007 Model: LT-A450XK8 VALVE + VALVE GUIDE Valve diam. 30.6 IN. (1.20) EX. 27.0 (1.06) Tappet clearance (when cold) 0.05 0.10 IN. (0.002 0.004) EX. 0.17 0.22 (0.007 0.009) 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. 0.010 0.037 (0.0004 0.0015) 0.030 0.057 (0.0012 0.0022) 5.000 5.012 (0.1968 0.1973) 4.975 4.990 (0.1958 0.1964) 4.955 4.970 (0.1950 0.1956) IN. & EX. IN. & EX. IN. & EX. IN. & EX. 0.9 1.1 (0.035 0.043) IN. & EX. IN. & EX. IN. & EX. 182 210 N (18.6 21.4 kgf, 41.0 47.2 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
CAMSHAFT + CYLINDER HEAD Cam height IN. EX. CYLINDER + PISTON + PISTON RING 33.450 33.504 (1.3169 1.3190) 33.470 33.524 (1.3177 1.3198) 33.15 (1.3051) 33.17 (1.3059) Camshaft journal oil clearance 0.028 0.059 (0.0011 0.0023) 0.150 0.032 0.066 (0.0059) (0.0012 0.0025) Camshaft journal holder I.D. 17.512 17.525 (0.6894 0.6899) 22.012 22.025 (0.8666 0.8671) Camshaft journal O.D. 17.466 17.484 (0.6876 0.6883) 21.959 21.980 (0.8645 0.8653) Camshaft runout 0.10 (0.004) Rocker arm I.D 12.000 12.018 IN. & EX. (0.4724 0.4731) Rocker arm shaft O.D 11.973 11.984 IN. & EX. (0.4713 0.4718) Cylinder head distortion 0.05 (0.002) Cylinder head cover distortion 0.05 (0.002) Compression pressure (Automatic-decomp. actuated) Approx. 1 000 kpa (10.0 kgf/cm², 142 psi) Piston-to-cylinder clearance 0.030 0.040 (0.0012 0.0016) Cylinder bore 84.000 84.015 (3.3070 3.3076) Piston diam. 83.965 83.980 (3.3057 3.3062) 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) 0.120 (0.0047) Nicks or Scratches 83.880 (3.3023) 0.05 (0.102) 7.9 (0.31) 7.7 (0.30) Model: LT-A450XK8 2/10 P-17, 24, 28, 33
Piston ring end gap 0.10 0.25 0.50 1st R (0.004 0.010) (0.020) Piston ring to groove clearance CONROD + CRANKSHAFT OIL PUMP 2nd R 0.10 0.30 (0.004 0.011) 1st 2nd Piston ring groove width 1.21 1.23 1st (0.0476 0.0484) 1.01 1.03 2nd (0.0398 0.0406) 2.51 2.53 Oil (0.0988 0.0996) Piston ring thickness 1.17 1.19 1st (0.0460 0.0468) 0.97 0.99 2nd (0.0382 0.0390) Piston pin bore I.D. 20.002 20.008 (0.7874 0.7877) Piston pin O.D. 19.992 20.000 (0.7870 0.7874) 0.50 (0.020) 0.180 (0.0071) 0.150 (0.0059) 20.030 (0.7885) 19.980 (0.7866) Conrod small end I.D. 20.006 20.014 (0.7876 0.7879) 20.040 (0.7889) Conrod deflection 3.0 (0.12) Conrod big end side clearance 0.10 0.65 (0.004 0.025) Conrod big end width 24.95 25.00 (0.982 0.984) Crank web to web width 70.9 71.1 (2.79 2.78) 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 3 000 r/min Model: LT-A450XK8 3/10 P-17, 24, 28, 33
CLUTCH DRIVE TRAIN Clutch wheel I.D. 140.0 140.2 (5.512 5.520) Clutch shoe 140.5 (5.53) No groove at any part Clutch engagement r/min. 1 700 2 200 r/min. Clutch lock-up r/min. 3 750 4 250 r/min. Except ratio Automatic transmission ratio Variable change (2.902 0.779) Secondary reduction ratio 2.733 (41/19 19/15) Final reduction ratio Front 3.600 (36/10) Rear 3.600 (36/10) Transfer gear ratio Low 2.562 (41/16) High 1.240 (31/25) Reverse 2.000 (32/16) Drive belt width 31.1 (1.22) Movable driven face spring free length 215.0 (8.46) Shift fork to groove clearance 0.10 0.30 (0.004 0.012) Shift fork groove width Shift fork thickness Reverse High Reverse High Front/rear output shaft bevel gear backlash Front drive (differential) gear backlash 5.50 5.60 (0.217 0.220) 5.50 5.60 (0.217 0.220) 5.30 5.40 (0.209 0.213) 5.30 5.40 (0.209 0.213) 0.03 0.15 (0.001 0.006) 0.05 0.10 (0.002 0.004) 30.1 (1.18) 204.3 (8.04) 0.50 (0.020) Final gear backlash 0.08 0.15 (0.003 0.005) 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
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 110 137.3 kpa (1.1 1.4 kgf/cm², 15.6 19.9 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 50:50. 250 ml Reservoir (0.26/0.22 US/lmp qt) 2 200 ml Engine (2.32 1.94 US/lmp qt) INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR ITEM SPECIFICATION NOTE Injector resistance 11.5 12.5 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
FI SENSORS ITEM SPECIFICATION NOTE CKP sensor resistance 200 250 Ω CKP sensor peak voltage 65 V and more When cranking IAP sensor input voltage 4.5 5.5 V IAP sensor output voltage 2.17 3.15 V at idle speed TP sensor input voltage 4.5 5.5 V TP sensor resistance Closed Approx. 1.17 kω Opened Approx. 4.30 kω TP sensor output voltage Closed 0.93 1.31 V Opened 3.64 4.82 V ECT sensor input voltage 4.5 5.5 V ECT sensor resistance 20 C (68 F) Approx. 2.45 kω 40 C (104 F) Approx. 1.15 kω 80 C (176 F) Approx. 0.31 kω 100 C (182 F) Approx. 0.18 kω IAT sensor input voltage 4.5 5.5 V IAT sensor output voltage Approx. 1.88 3.06 V at 20 C (68 F) IAT sensor resistance 20 C (68 F) 2.22 3.11 kω 40 C (104 F) 1.00 1.56 kω TO sensor resistance 19 20 kω TO sensor voltage Normal 0.4 1.4 V Leaning 3.7 4.4 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
THROTTLE BODY ITEM Bore size I.D. No. Idle r/min. Throttle cable play STANDARD/SPECIFICATION 35 mm 11H0 1 500 ± 100 r/min. 3 5 mm (0.1 0.2 in) ELECTRICAL ITEM STANDARD/SPECIFICATION NOTE Spark plug NGK: CR6E Type DENSO: U20ESR-N Gap 0.7 0.8 (0.028 0.031) Spark performance Over 8 (0.3) at 1 atm. Ignition coil resistance Terminal Primary 0.1 0.6 Ω Ground Secondary 12 19 kω Plug cap Terminal Generator coil resistance 0.1 1.0 Ω Generator Max. output Approx. 375 W at 5 000 r/min Generator no-load voltage (when engine is cold) 65 V (AC) and more at 5 000 r/min. Regulated voltage 13.5 15.5 V at 5 000 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
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 12.5 22.5 (0.5 0.9) Rear brake pedal free travel 20 30 (0.8 1.2) Front brake disc thickness 3.3 3.7 (0.13 0.15) Front brake disc runout 3.0 (0.20) 0.30 (0.012) Front master cylinder bore 14.000 14.043 (0.5512 0.5529) Front master cylinder piston diam. 13.957 13.984 (0.5495 0.5506) Front brake caliper cylinder bore 33.960 34.010 (1.3370 1.3390) Front brake caliper piston diam. 33.878 33.928 (1.3338 1.3357) Rear brake lever play 6 8 (0.2 0.3) Brake fluid type DOT 4 Model: LT-A450XK8 8/10 P-17, 24, 28, 33
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 25 8-12, tubeless Rear AT 25 10-12, 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
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 2 500 ml change (2.6/2.2 US/lmp qt) Filter change Overhaul 2 700 ml (2.8/2.4 US/lmp qt) 3 200 ml (3.4/2.8 US/lmp qt) Model: LT-A450XK8 10/10 P-17, 24, 28, 33