4 STROKE VALVE + VALVE GUIDE CAMSHAFT + CYLINDER HEAD SERVICE DATA Valve diam. 36.0 (1.42) 33.0 (1.30) Tappet clearance (when cold) 0.10 0.20 (0.004 0.008) 0.20 0.30 (0.008 0.012) 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 Cam height & 0.010 0.037 (0.0004 0.0015) 0.030 0.057 (0.0012 0.0022) 5.500 5.512 (0.2165 0.2170) 5.475 5.490 (0.2156 0.2161) 5.455 5.470 (0.2148 0.2154) & & & & 0.9 1.1 (0.035 0.043) & & & 182 210 N (18.6 21.4 kgf, 41.0 47.2 lbs) at length 36.35 mm (1.43 in) 0.35 (0.014) 0.05 (0.002) 0.5 (0.02) 0.03 (0.001) 46.1 (1.81) Camshaft journal oil clearance Camshaft journal holder I.D. Camshaft journal O.D. & & & 36.330 36.380 (1.4303 1.4323) 35.300 35.350 (1.3898 1.3917) 0.019 0.053 (0.0007 0.0021) 22.012 22.025 (0.8666 0.8671) 21.972 21.993 (0.8650 0.8659) Date: July 5, 2006 Model: LT-A700XK7 36.030 (1.4185) 35.000 (1.3780) 0.150 (0.0059) Model: LT-A700XK7 1/7
Camshaft runout 0.10 (0.004) Cylinder head distortion 0.05 (0.002) CYLINDER + PISTON + PISTON RING 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 102.000 102.015 (4.0157 4.0163) Piston diam. 101.965 101.980 (4.0144 4.0150) Measure at 15 mm (0.6 in) from the skirt end. Cylinder distortion Piston ring free end gap Piston ring end gap Piston ring to groove clearance 1st R Approx. 10.4 (0.41) 2nd RN Approx. 14.3 (0.56) 1st 2nd R RN 0.10 0.25 (0.004 0.010) 0.10 0.25 (0.004 0.010) 1st 2nd Piston ring groove width 0.83 0.85 1st (0.0327 0.0335) 1.30 1.32 (0.0512 0.0520) 2nd 1.01 1.03 (0.0398 0.0406) Oil 2.01 2.03 (0.0791 0.0799) Piston ring thickness 1st 1.08 1.10 (0.0425 0.0433) 2nd 0.97 0.99 (0.0382 0.0390) Piston pin bore I.D. 23.002 23.008 (0.9056 0.9058) Piston pin O.D. 22.992 23.000 (0.9052 0.9055) 0.120 (0.0047) Nicks or Scratches 101.880 (4.0110) 0.05 (0.102) 8.3 (0.33) 11.4 (0.45) 0.50 (0.020) 0.50 (0.020) 0.180 (0.0071) 0.150 (0.0059) 23.030 (0.9067) 22.980 (0.9047) Model: LT-A700XK7 2/7
CONROD + CRANKSHAFT OIL PUMP CLUTCH DRIVE TRAIN Conrod small end I.D. 23.006 23.014 (0.9057 0.9061) Conrod deflection Conrod big end side clearance 0.10 0.75 (0.004 0.030) Conrod big end width 24.95 25.00 (0.982 0.984) Crank web to web width 72.9 73.1 (2.87 2.88) Crankshaft runout 23.040 (0.9071) 0.30 (0.012) 1.0 (0.04) 0.08 (0.003) Oil pressure (at 60 C, 140 F) Above 140 kpa (1.4 kgf/cm², 20 psi) Below 180 kpa (1.8 kgf/cm², 26 psi) 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 1 600 2 000 r/min Clutch lock-up r/min 3 500 4 100 r/min Except ratio Automatic transmission ratio Variable change (2.763 0.780) Secondary reduction ratio 2.158 (40/21 17/15) Final reduction ratio Front 3.600 (36/10) Rear 3.600 (36/10) Transfer gear ratio Low 2.563 (41/16) High 1.240 (31/25) Reverse 1.882 (32/17) Drive belt width 34.7 (1.37) Movable driven face spring free length 153.0 (6.02) Shift fork to groove clearance 0.10 0.30 (0.004 0.012) 33.7 (1.33) 145.4 (5.72) 0.50 (0.020) Model: LT-A700XK7 3/7
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) Rear drive (final) gear backlash 0.08 0.015 (0.003 0.006) Front differential gear oil type Hypoid gear oil SAE #90, API grade GL-5 Rear drive gear oil type Mobil 424 or equivalent gear oil Front differential gear oil capacity 500 ml (16.9/17.6 US/lmp oz) Rear drive gear oil capacity 770 ml (26.0/27.1 US/lmp oz) 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) ECT sensor resistance 20 C (68 F) Approx. 2.45 kω 50 C (122 F) Approx. 0.811 kω 80 C (176 F) Approx. 0.318 kω 110 C (230 F) Approx. 0.142 kω Radiator cap valve opening pressure Cooling fan thermo-switch operating temperature Engine coolant type Engine coolant 110 140 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. Reservoir 250 ml (0.26/0.22 US/lmp qt) Engine 2 200 ml (2.32 1.94 US/lmp qt) INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR ITEM SPECIFICATION NOTE Injector resistance 11 13 Ω at 20 C (68 F) Fuel 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 (2.9 kgf/cm², 41 psi) Model: LT-A700XK7 4/7
FI SENSORS+ SECONDARY THROTTLE VALVE ACTUATOR ITEM SPECIFICATION NOTE CKP sensor resistance 150 250 Ω CKP sensor peak voltage 5.0 V and more When cranking IAP sensor input voltage IAP sensor output voltage Approx. 2.63 V at idle speed TP sensor input voltage TP sensor resistance Closed Approx. 1.17 kω Opened Approx. 4.30 kω TP sensor output voltage Closed Approx. 1.17 V Opened Approx. 4.30 V ECT sensor input voltage ECT sensor resistance Approx. 2.45 kω at 20 C (68 F) IAT sensor input voltage IAT sensor resistance Approx. 1.60 kω at 20 C (68 F) 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 THROTTLE BODY ITEM Bore size I.D. No. Idle r/min Fast idle r/min Throttle cable play STANDARD/SPECIFICATION 42 mm 31G0 1 300 ± 100 r/min 1 500 2 000 r/min (When cold engine) 3 5 mm (0.12 0.20 in) ELECTRICAL ITEM STANDARD/SPECIFICATION NOTE Spark plug Type NGK: CR6E DENSO: U20ESR-N Gap 0.7 0.8 (0.028 0.031) Spark performance Over 8 (0.3) at 1 atm. CKP sensor resistance 150 250 Ω CKP sensor peak voltage 5.0 V and more Ignition coil resistance Primary 0.1 0.6 Ω Terminal Ground Secondary 12 19 kω Plug cap Terminal Ignition coil primary peak voltage 80 V and more Generator coil resistance 0.4 1.0 Ω Generator no-load voltage (when engine is cold) 75 V (AC) and more at 5 000 r/min Model: LT-A700XK7 5/7
ITEM STANDARD/SPECIFICATION NOTE Regulated voltage 13.5 15.5 V at 5 000 r/min Starter relay resistance 3 5 Ω Battery Type designation YTX20CH-BS Capacity 12 V 64.8 kc (18 Ah)/10 HR Fuse size HI Headlight LO Power source Ignition 15 A Fuel Fan 15 A Main 30 A WATTAGE ITEM STANDARD/SPECIFICATION P-24, 28, 33 P-17 Headlight HI 35 2 LO 35 2 Auxiliary headlight 35 Brake light/taillight 21/5 Backup 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 Differntial 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 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) 3.0 (0.20) 0.30 (0.012) Model: LT-A700XK7 6/7
ITEM STANDARD/SPECIFICATION LIMIT Rear brake lever play 6 8 (0.2 0.3) Brake fluid type DOT 4 Steering angle 46 (right & left) Turning radius 3.1 m (10.2 ft) Toe-out (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 FUEL + OIL 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 Front 4.0 (0.16) Rear 4.0 (0.16) Front shock absorber spring adjustor 2/5 position Rear shock absorber spring adjuster 2/5 position 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 Butyl P-28, 33 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. An unleaded gasoline is recommended. The others Fuel tank capacity 17.5 L (4.6/3.8 US/lmp gal) Engine oil type SAE 10W-40, API SF/SG or SH/SJ with JASO MA Engine oil capacity Change 2 300 ml (2.4/2.0 US/lmp qt) Filter change Overhaul 2 500 ml (2.6/2.2 US/lmp qt) 3 000 ml (3.2/2.6 US/lmp qt) Model: LT-A700XK7 7/7