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Valves
Head diameter: Inlet Exhaust
R45 R50 34mm (1.34") 32mm
(1.26")
R60 R65 up to '80 38mm (1.50") 34mm
(1.34")
R65 '81 on, R65LS 40mm (1.58") 36mm
(1.42")
R75, all 800cc models 42mm (1.65") 38mm
(1.50")
R90/6 R90S R100/7 42mm (1.65") 40mm
(1.58")
All other 1000cc models 44mm (1.73") 40mm
(1.58")
Head rim minimum thickness:
/5 /6 /7 1.0mm (0.0394") 1.0mm
(0.0394")
R80G/S R80ST R80RT '83-'84 0.8mm (0.0315") 0.8mm
(0.0315")
R45 R65 R65LS 1.0-1.5mm 1.0-1.2mm
(0.0394-0.0591") (0.0394-
0.0472")
Head maximum runout:
/5 /6 /7 0.025mm (0.0010") 0.025mm
(0.0010")
R80G/S R80ST R80RT '83-84 0.020mm (0.0008") 0.020mm
(0.0008")
Overall length:
R50/5 102.6-103.0mm 102.1-
102.5mm
(4.0394-4.0551") (4.0197-
4.0354")
R45 R65 R65LS 98.8-100.2mm 99.1-
99.5mm
(3.8898-3.9449") (3.9016-
3.9173")
R60/5 R60/6 98.2-98.5mm 97.2-
97.5mm
(3.8661-3.8780") (3.8268-
3.8386")
R60/7 99.2-99.5mm 98.2-
98.5mm
(3.9055-3.9173") (3.8661-
3.8780")
All other models 98.4-98.8mm 98.4-
98.8mm
(3.8740-3.8898") (3.8740-
3.8898")
Valve Guides
Length overall:
/5 /6 except R90S 54mm (2.1260")
R90S, /7 48mm (1.8898")
R45 R65 R65LS 45mm (1.7717")
R80G/S R80ST R80RT '83-'84 44mm (1.7323")
Outside diameter:
/5 /6 /7 R80G/S R80ST R80RT '83-84 14.050-14.061mm (0.5532-
0.5536")
R45 R65 R65LS 14mm (0.5512")
Inside diameter:
/5 /6 /7 8mm (0.3150")
R45 R65 R65LS 7mm (0.2756")
R80G/S R80ST R80RT '83-84 8.000-8.015mm (0.3150-
0.3156")
Bore in cylinder head:
/5 /6 /7 R45 R65 R65LS 14mm (0.5512")
R80G/S R80ST R80RT '83-84 14.000-14.018mm (0.5512-
0.5519")
Interference fit in cylinder head:
/5 /6 /7 0.032-0.061mm (0.0013-
0.0024")
All other models N/Av
Oversizes available 0.1 & 0.2mm (0.004 & 0.008")
Valve stem/guide standard clearance: Inlet Exhaust
R50/5 0.040-0.070mm 0.050-
0.080mm
(0.0016-0.0028")
(0.0020-0.0032")
R45 R65 R65LS 0.025-0.055mm 0.040-
0.070mm
(0.0010-0.0022")
(0.0016-0.0028")
R60 0.050-0.080mm 0.065-
0.095mm
(0.0020-0.0032")
(0.0026-0.0037")
All other models 0.050-0.080mm 0.050-
0.080mm
(0.0020-0.0032")
(0.0020-0.0032")
Inlet and exhaust valve stem/guide max. permissible clearance -
measured
at top of guide:
R45 R65 R65LS 0.10mm (0.0039")
All other models 0.15mm (0.0059")
Valve seats
Outside diameter: Inlet Exhaust
R50/5 36.175-36.200mm 36.140-
36.150mm
(1.4242-1.4252")
(1.4228-1.4232")
R45 36.2mm (1.4252") 36.2mm
(1.4252")
R60 39.175-39.200mm 39.175-
39.200mm
(1.5423-1.5433")
(1.5423-1.5433")
R65 R65LS 39.2mm (1.5433") 39.2mm
(1.5433")
R75/5 43.175-43.200mm 43.140-
43.150mm
(1.6998-1.7008")
(1.6984-1.6988")
R75/6 R90/6 R90S 43.175-43.200mm 43.175-
43.200mm
(1.6998-1.7008")
(1.6998-1.7008")
R75/7 R80/7 R100/7 43.175-43.200m 43.134-
43.200mm
(1.6998-1.7008")
(1.6982-1.7008")
R80G/S R80ST R80RT '83-84 43.175-43.200m 43.134-
43.150mm
(1.6998-1.7008")
(1.6982-1.6988")
All other 1000cc models 45.175-45.200mm 45.175-
45.200mm
(1.7785-1.7795")
(1.7785-1.7795")
Bore in cylinder head - inlet and exhaust:
R50/5 36.00-36.025mm (1.4173-
1.4183")
R45 36mm (1.4173")
R60 39.00-39.025mm (1.5354-
1.5364")
R65, R65LS 39mm (1.5354")
All 745cc 800cc 900cc, R100/7 43.000-43.025mm (1.6929-
1.6939")
All other 1000cc models 45.000-45.025mm (1.7717-
1.7727")
Interference fit in cylinder head: Inlet Exhaust
R50/5 R75/5 0.150-0.200mm 0.115-
0.150mm
(0.0059-0.0079")
(0.0045-0.0059")
R45 R65 R65LS N/Av N/Av
R75/7 R80/7 R100/7 R80G/S R80ST
R80RT '83-'84 0.150-0.200mm 0.109-
0.150mm
(0.0059-0.0079")
(0.0043-0.0059")
All other models 0.150-0.200mm 0.150-
0.200mm
(0.0059-0.0079")
(0.0059-0.0079")
Seat angle:
Main seating face 45 deg
At combustion chamber 15 deg
At inlet/exhaust port 75 deg
Seat width:
Inlet 1.5mm (0.0591")
Exhaust 2.0mm (0.0787")
Seat oversizes available 0.2 0.4mm (0.0079 0.0168")
Valve springs
Wire thickness 4.25mm (0.1673")
Spring free length - approx:
Blue or green code 43.5mm (1.7126")
Brown code 46.0mm (1.811")
Spring force at test length:
At 37.6mm (1.4803") 27.84-30.16 kp (61.30-66.5
lb)
At 28.5mm (1.1221") 70.00-72.80 kp (154.30-160.5
lb)
Rocker gear
Arm ID -/5 18.032-18.059mm (0.7099-
0.7110")
Bush OD -/5 18.012-18.030mm (0.7091-
0.7098")
Arm/bush clearance -/5 0.002-0.047mm (0.00008-
0.00185")
Bush ID /5 14.532-14.559mm (0.5721-
0.5732")
Shaft OD /5 14.512-14.530mm (0.5713-
0.5720")
Bush/shaft clearance /5 0.002-0.047mm (0.00008-
0.00185")
Arm axial float:
R80 R80RT 1985 0.03-0.07mm (0.0012-0.0028")
All other models Nil, but arm must be free to
move
Camshaft
Front (alternator end) bearing bore 40.000-40.039mm (1.5748-
1.5763")
Front flange bearing OD 39.984-40.000mm (1.5742-
1.5748")
Front flange bearing ID 25.000-25.013mm (0.9843-
0.9848")
Camshaft front bearing journal OD 24.967-24.980mm (0.9830-
0.9835")
Camshaft radial clearance - at
front bearing 0.020-0.046mm (0.0008-
0.0018")
Rear (flywheel end) bearing bore 24.000-24.021mm (0.9449-
0.9457")
Camshaft rear bearing journal OD 23.967-23.980mm (0.9436-
0.9441")
Camshart radial clearance - at
rear bearing 0.020-0.054mm (0.0008-
0.0021")
Camshaft end float 0.080-0.120mm (0.0032-
0.0047")
Base circle 28mm (1.1024")
Cam lift:
R50/5 R60 6.198mm (0.2440")
All other models 6.756mm (0.2660")
Maximum permissible runout of ATU
shaft - /5 /6 /7 up to '78 0.02mm (0.0008")
Cylinders
Type:
All models up to 1980 Cast iron sleeve joined to aluminium
alloy
finned jacket by 'Al-Fin' process
R45,R65,R65LS '81 on Aluminium alloy barrel with 'Nikasil'
plated bore
1000cc and 800cc, '81 on Aluminium alloy barrel with 'Galnikal'
plated
bore
Cylinder standard bore ID - at specified bore size code:
A B C
R50/5 67.000mm 67.010mm
67.020mm
(2.7368") (2.6382")
(2.6386")
R45 69.995-70.005mm 70.005-70.015mm
70.015-70.025mm
(2.7557-2.7561") (2.7561-2.7565")
(2.7565-2.7569")
R60/5,R60/6 73.500mm 73.510mm
73.520mm
(2.8937") (2.8941")
(2.8945")
R60/7 73.500-73.510mm 73.510-73.520mm
73.520-73.530mm
(2.8937-2.8941") (2.8941-2.8945")
(2.8945-2.8949")
R65,R65LS 81.995-82.005mm 82.005-82.015mm
82.015-82.025mm
(3.2281-3.2285") (3.2285-3.2289")
(3.2289-3.2293")
R75/5,R75/6 82.000mm 82.010mm
82.020mm
(3.2283") (3.2287")
(3.2291")
R75/7 82.005-82.015mm 82.015-82.025mm
82.025-82.035mm
(3.2285-3.2289") (3.2289-3.2293")
(3.2293-3.2297")
All 800cc models 84.795-84.805mm 84.805-84.815mm
84.815-84.825mm
(3.3384-3.3388") (3.3388-3.3392")
(3.3392-3.3396")
R90/6,R90S 90.000mm 90.010mm
90.020mm
(3.5433") (3.5437")
(3.5441")
All 1000cc models 94.005-94.015mm 94.015-94.025mm
94.025-94.035mm
(3.7010-3.7014") (3.7014-3.7018")
(3.7018-3.7022")
Rebore sizes:
/5,/6,R60/7,R75/7 - 1st 0.50mm (0.020")
/5,/6,R60/7,R75/7 - 2nd 1.00mm (0.040")
R45&R65 to '80,R80/7 - 1st 0.25mm (0.010")
R45&R65 to '80,R80/7 - 2nd 0.50mm (0.020")
All 1000cc models to '80 0.25mm (0.010")
All models '81 on rebores not possible, pistons and
cylinders
must be renewed when excessively
worn
Maximum ovality:
R45,R65,R65LS 0.005mm (0.0002")
R80G/S,R80ST - 20mm (0.8") from top of bore 0.005mm (0.0002")
R80G/S,R80ST - 115mm (4.5") from top of bore 0.010mm (0.0004")
All other models 0.010mm (0.0004")
Maximum taper:
/5,/6 0.010mm (0.0004")
All other models 0.020mm (0.0008")
Pistons
Standard OD - at specified size code:
A B C
R50/5 66.960mm 66.970mm
66.980mm
(2.6362") (2.6366")
(2.6370")
R45 69.955-69.965mm 69.965-69.975mm
69.975-69.985mm
(2.7541-2.7545") (2.7545-2.7549")
(2.7549-2.7553")
R60/5,R60/6 73.460mm 73.470mm
73.480mm
(2.8921") (2.8925")
(2.8929")
R60/7 73.470mm 73.480mm
73.490mm
(2.8925") (2.8929")
(2.8933")
R65,R65LS 81.955-81.965mm 81.965-81.975mm
81.975-81.985mm
(3.2266-3.2270") (3.2270-3.2274")
(3.2274-3.2278")
R75/5,R75/6 81.960mm 81.970mm
81.980mm
(3.2268") (3.2272")
(3.2276")
R75/7 81.965mm 81.975mm
81.985mm
(3.2270") (3.2274")
(3.2278")
All 800cc models 84.765mm 84.775mm
84.785mm
(3.3372") (3.3376")
(3.3380")
R90/6,R90S 89.960mm 89.970mm
89.980mm
(3.5417") (3.5421")
(3.5425")
All 1000cc models 93.960mm 93.970mm
93.980mm
(3.6992") (3.6996")
(3.7000")
Standard piston/cylinder clearance:
/5,/6 0.035-0.045mm (0.0014-0.0018")
R60/7 0.020-0.040mm (0.0008-0.0016")
R75/7 0.019-0.041mm (0.0007-0.0016")
R80/7 0.023-0.047mm (0.0009-0.0029")
R45 & R65 up to '80 0.030-0.050mm (0.0012-0.0020")
All 1000cc models up to '80 0.028-0.052mm (0.0011-0.0021")
All models '81 on 0.030-0.040mm (0.0012-0.0016")
Maximum permissible piston/cylinder clearance:
/5,/6 0.120mm (0.0047")
All other models 0.080mm (0.0032")
Piston weight group + or - stamped in piston crown -
both
pistons must be of the same weight
group,
i.e. carry the same marking.
Piston rings
Top:
Type Plain, rectangular section
Thickness:
/5,/6 1.790-1.810mm (0.705-0.0713")
R45 1.478-1.490mm (0.582-0.0587")
All other models 1.728-1.740mm (0.0680-0.0685")
End gap - installed:
R50,R60 0.25-0.40mm (0.0098-0.0158")
R45 0.25-0.45mm (0.0098-0.0177")
R75/5,R75/6,R90/6,R90S 0.30-0.45mm (0.0118-0.0177")
/7 '81 on 0.40-0.65mm (0.0158-0.0256")
All other models 0.30-0.50mm (0.0118-0.0197")
Side clearance:
/5,/6 0.060-0.070mm (0.0024-0.0028")
/7 0.060-0.090mm (0.0024-0.0035")
All other models 0.050-0.082mm (0.0020-0.0032")
Second:
Type Plain, with stepped or tapered face
Thickness
/5,/6 2.030-2.050mm (0.0799-0.0807")
/7, R45 up to '80 2.010-2.022mm (0.0791-0.0796")
All other models 1.978-1.990mm (0.0779-0.0784")
End gap - installed:
R50,R60 0.25-0.40mm (0.0098-0.0158")
R45 0.25-0.45mm (0.0098-0.0177")
R80G/S,R80ST 0.30-0.50mm (0.0118-0.0197")
/7 '81 on 0.40-0.65mm (0.0158-0.0256")
All other models 0.30-0.45mm (0.0118-0.0177")
Side clearance:
/5,/6 0.050-0.060mm (0.0020-0.0024")
All other models 0.040-0.072mm (0.0016-0.0028")
Oil scraper:
Type One piece
Thickness:
/5,/6 4.010-4.030mm (0.1579-0.1587")
/7 4.010-4.022mm (0.1579-0.1584")
R80G/S,R80ST,R45 '81 on 3.478-3.490mm (0.1369-0.1374")
R45 up to '80 3.510-3.522mm (0.1382-0.1387")
R65,R65LS 3.978-3.990mm (0.1566-0.1571")
End gap - installed:
R50/5,R60/5 0.20-0.35mm (0.0079-0.0138")
R60/6,R60/7 0.25-0.35mm (0.0098-0.0138")
R45 0.25-0.45mm (0.0098-0.0177")
All other models 0.25-0.40mm (0.0098-0.0158")
Side clearance:
/5,/6 0.030-0.040mm (0.0012-0.0016")
R60/7 0.020-0.050mm (0.0008-0.0020")
All other models 0.030-0.062mm (0.0012-0.0024")