2011r Service data.pdf

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Model: RM-Z450L1 E-03, 19, 28
Date: May 25, 2010
SERVICE DATA
VALVE + GUIDE
ITEM
Valve diam.
IN.
EX.
Tappet clearance (when cold)
IN.
EX.
Valve guide to valve stem
clearance
IN.
EX.
Valve stem deflection
Valve guide I.D.
Valve stem O.D.
IN. & EX.
IN. & EX.
IN.
EX.
Valve stem runout
Valve seat width
Valve head radial runout
Valve spring free length
Valve spring tension
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
STANDARD
36
(1.4)
31
(1.2)
0.09 – 0.16
(0.004 – 0.006)
0.17 – 0.24
(0.007 – 0.009)
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)
—
—
146 – 168 N
(14.9 – 17.1 kgf, 32.8 – 37.7 lbs)
at length 30.9 mm (1.22 in)
Unit: mm (in)
LIMIT
—
—
—
—
—
—
0.25
(0.010)
—
—
—
0.05
(0.002)
—
0.03
(0.001)
35.8
(1.41)
—
1/13
CAMSHAFT + CYLINDER HEAD
ITEM
Cam height
IN.
EX.
Camshaft journal oil clearance
Camshaft journal holder I.D.
Camshaft journal O.D.
Camshaft runout
Cam chain pin
Cylinder head distortion
IN. & EX.
IN. & EX.
IN. & EX.
STANDARD
35.18 – 35.23
(1.385 – 1.387)
34.43 – 34.48
(1.356 – 1.357)
0.032 – 0.066
(0.001 – 0.002)
22.012 – 22.025
(0.8667 – 0.8671)
21.959 – 21.980
(0.8645 – 0.8654)
—
14th pin
—
Unit: mm (in)
LIMIT
34.88
(1.373)
34.13
(1.344)
0.150
(0.0059)
—
—
0.10
(0.004)
—
0.05
(0.002)
Unit: mm (in)
LIMIT
—
0.120
(0.0047)
Nicks or
scratches
95.880
(3.7748)
0.05
(0.002)
7.0
(0.28)
0.50
(0.020)
0.180
(0.007)
—
—
—
—
—
19.030
(0.7492)
18.980
(0.7472)
CYLINDER + PISTON + PISTON RING
ITEM
Compression pressure
(Automatic decomp. actuated)
Piston to cylinder clearance
Cylinder bore
Piston diam.
Cylinder distortion
Piston ring free end gap
Piston ring end gap
Piston ring to groove clearance
Piston ring groove width
1st
1st
1st
1st
STANDARD
400 kPa (4.0 kgf/cm
2
, 57 psi) and more
0.035 – 0.045
(0.0014 – 0.0018)
96.000 – 96.015
(3.7795 – 3.7801)
95.960 – 95.975
(3.7779 – 3.7785)
Measure at 15 mm (0.6 in) from the skirt end.
—
Approx. 8.7 (0.34)
0.08 – 0.20
(0.003 – 0.008)
—
0.78 – 0.80
(0.0307 – 0.0315)
1.30 – 1.32
(0.0512 – 0.0520)
2.01 – 2.03
(0.0791 – 0.0799)
0.71 – 0.76
(0.0279 – 0.0299)
1.08 – 1.10
(0.0425 – 0.0433)
19.002 – 19.008
(0.7425 – 0.7433)
18.995 – 19.000
(0.7478 – 0.7480)
Oil
Piston ring thickness
1st
Piston pin bore
Piston pin O.D.
2/13
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
Conrod deflection
Conrod big end side clearance
Conrod big end width
Crank web to web width
Crankshaft runout
STANDARD
19.010 – 19.018
(0.7484 – 0.7487)
—
0.20 – 0.65
(0.008 – 0.026)
19.75 – 19.80
(0.778 – 0.780)
61.9 – 62.1
(2.437 – 2.445)
—
Unit: mm (in)
LIMIT
19.040
(0.7496)
3.0
(0.12)
1.0
(0.04)
—
—
0.08
(0.003)
OIL PUMP
ITEM
Oil pressure (at 50 °C, 122 °F)
STANDARD
50 kPa (0.5 kgf/cm
2
, 7.1 psi)
at 4 000 r/min
LIMIT
—
Unit: mm (in)
LIMIT
—
2.77
(0.109)
13.05
(0.514)
0.10
(0.004)
49.4
(1.94)
CLUTCH
ITEM
Clutch lever clearance
Drive plate thickness
(No.1 & No.2)
Drive plate claw width
(No.1 & No.2)
Driven plate distortion
Clutch spring free length
STANDARD
2–3
(0.08 – 0.12)
3.07 – 3.23
(0.121 – 0.127)
13.85 – 13.95
(0.545 – 0.549)
—
51.94
(2.045)
RADIATOR + ENGINE COOLANT
ITEM
ECT sensor resistance
STANDARD/SPECIFICATION
20 °C
(68 °F)
50 °C
(122 °F)
80 °C
(176 °F)
110 °C
(230 °F)
Approx. 2.58 kΩ
Approx. 0.77 kΩ
Approx. 0.28 kΩ
Approx. 0.12 kΩ
LIMIT
—
—
—
—
—
—
—
Radiator cap valve opening
pressure
Engine coolant type
Engine coolant capacity
95 – 125 kPa
(0.95 – 1.25 kgf/cm², 14 – 18 psi)
Use an anti-freeze/coolant compatible with alumi-
num radiator, mixed with distilled water only, at the
ratio of 50:50.
950 ml
(1.0/0.8 US/lmp qt)
3/13
TRANSMISSION + DRIVE CHAIN
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratios
STANDARD
2.625 (63/24)
3.846 (50/13)
1.800 (27/15)
1.471 (25/17)
1.235 (21/17)
1.050 (21/20)
0.909 (20/22)
0.1 – 0.3
(0.004 – 0.012)
5.0 – 5.1
(0.197 – 0.201)
4.8 – 4.9
(0.189 – 0.193)
DID 520 MXV4
114
15.0 (0.59)
12.8 (0.50)
40 – 50
(1.6 – 2.0)
Low
2nd
3rd
4rh
Top
Shift fork to groove clearance
Shift fork groove width
Shift fork thickness
Drive chain
Drive chain plate height
No.1, 2, 3
No.1, 2, 3
No.1, 2, 3
Type
Links
Inner
Outer
Unit: mm (in) Except ratio
LIMIT
—
—
—
—
—
—
—
0.5
(0.02)
—
—
—
—
12.75
(0.502)
11.20
(0.441)
—
Drive chain slack
INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR
ITEM
Injector resistance
Fuel pump discharge amount
Fuel pressure regulator operating
set pressure
SPECIFICATION
9.5 – 11.5
Ω
at 20 °C (68 °F)
89 ml (3.0/ 3.1 US/lmp oz) and more
/10 sec.
Approx. 294 kPa (2.94 kgf/cm², 41.81 psi)
NOTE
4/13
FI SENSORS
ITEM
CKP sensor resistance
CKP sensor peak voltage
Crankshaft rotation signal sensor
resistance
Crankshaft rotation signal sensor
peak voltage
IAP sensor input voltage
IAP sensor output voltage
TP sensor input voltage
TP sensor output voltage
ECT sensor input voltage
ECT sensor resistance
IAT sensor input voltage
IAT sensor resistance
TO sensor resistance
TO sensor voltage
STANDARD/SPECIFICATION
80 – 120
Ω
2.8 V and more
0.1 – 0.8
Ω
3.5 V and more
4.5 – 5.5 V
0.98 – 2.86 V at idle speed
4.5 – 5.5 V
Closed
Approx. 0.6 V
Opened
Approx. 3.9 V
4.5 – 5.5 V
Approx. 2.58 kΩ at 20 °C (68 °F)
4.5 – 5.5 V
Approx. 2.58 kΩ at 20 °C (68 °F)
16.5 – 22.3 kΩ
Normal
0.4 – 1.4 V
Leaning
GP switch voltage
Injector voltage
3.7 – 4.4 V
0.6 V and more
Battery voltage
When
leaning 65°
From 1st to Top
NOTE
THROTTLE BODY
ITEM
Bore size
I.D. No.
Idle r/min
Throttle cable play
Hot starter lever clearance
SPECIFICATION
43 mm
28H3
2 000 ± 100 r/min
2 – 4 mm
(0.08 – 0.16 in)
2 – 3 mm
(0.08 – 0.12 in)
5/13

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