":'.:' .~ ., , ..

CONTENTS

STAGE

1. Cylinder Head Gasket, Piston &, Piston Rings

............ ,:, .' _........ ·1 .

-'" STAG E II

1. Piston & Piston Rings 2

- .c,'·

Valve MeJ:hanis!TI

. ,_ , ..

r' ,;

"3,_. 1n,uke&,fxhaust Syst~ms

.2.,

.... ~'

,"_ " ' : : ".T .. · ,·,..,. .. ·.-- ",,'" ., ,'_ " __ , 3

. . 4'

.......... , ., •.•........ ', :: .. _~.';:;-'.":-" _~."' , :"-;~;~4~" __

'. 4. ,h' hel. .Syst!!~". & .. ,ft,c.ceJerator Linka.ge

. '. .

... ~,,,: :' ... "', .~~ ': } ,../

'j;.

STAGE III

Cylinder Head

...

. ~ 6

1.

.. :~ ., ::~;:;:~: ~~g~~~-~~.~: .'~~ ;;':~'~: .,.:: .~- :~ .. ::, ;:2:\,··:,1,'; ~

,~4~ .,' CliIJln~Ctj:l1g~B:Q.d.Jir:atlksl!aft_& .ffVwheel .. ~ .. ,~, •.. ~ .. _,: :, _" ;"~ , ··· .. · .. ', .. ,' .. 16

~', -.~:>_!-.--,,_ ~.~"': ... " .. ':' ,''''.-' .r,

'5. Valve Mechanism 18

;", ":-

6. "Lubrication System .-'.'-- ,.';'~~ .. : :: .•. ., ' - : - ~ , .. 24

7. Intake' & Exhaust System .. .. : : :.~.~:: ., ~ ~ 27

8. Fuel System

................................................................... : .. · .. ····,'·: .... ., .. ···29

9. Accelerator linkage 31

10. Ignition System Components & Cooling System 32

. ": .. 11. ,': . .Engin,~,MOJmts; Ttansmissien .Houslng&. S.UJlP·orts " , , ; -,. : 33

. " - ., -

12. Service Standards List 34

CYLINDER HEAD GASKET, PISTON & PISTON RINGS

1

_.-.c_,

.~>._ ..

AT-V I

~~1i.a-'3tJ!" L. 'd:~) -z:tn66e.c:) 8:~.!:t,a- ~~ I::

f:::0;<, r /' ~ a- ~!i:lE L T rfJ t) i -t 0' ••

BTAGE I

Without a.lt~ring thedispJ~cement {l,;-166 cc). thpp_istons have been established to increase tne.compressiooratio.

""., .

. ~ 1)..:"- $I'" ';I't-: jj 7Jr ';I "~" E::7.1' > & e j " :/ f) :..- ?

. '. ;';.y, _1.. CYLINDER HE.AIl'GASKE:F!PfSION...&,P.JSTON'

:., '.','., RINGS. ,;,: ,

(1.) Main modifications.

a. Cylinder head gasket.

III .=t'Jd:' j£~

'a. ~ I) :; 7' A. ';t r';lf.7. T'J r

'··.c.' :'I±~l:t,i-j~®:~.;t!;:o'),,;.JElftil<fCl) if..~ i- ~5l!Li L t:_'Q'

.h._ I:::';J.. r :.--

c'.· .; . .J#·iIl.l'it £b~k;T.I'::' .. (,7.5.t2.1l&6.c.(\.).lB.llHt.fu M<' L

. "'. Due to. increaseof:j:CO/i'OPl"8ssion.ratio, the thickness upon assembling has been revised.

b. Piston

"'.:-- -,

J" Withouta!tering ... ili(;Ldi.spJaceITlEJJ_t·{15¢',.-J ;r66 ... ~. ; cd: .tlJe:cDmpFEssiory,·atiohas· bee'n ·irlCreased. c .. Piston rings.'

.. Two coraprsssron rings with. thickness of 1 rnm are utilized and the oil ring is of three-piece type with the thickness of 2.5 mm.

1:::''7, r /' .1) :"-"If

~> 7' v~;;.j';9 .:;, IJ :.-- 7'" (j: ~ ~ 1 mm.J)tJ) fu 2 1: [~If:l L, T -1 n- I J /' f (1.7. I) - e -.7. -7 -1 :1 c L, ~ ~ Ii 2. 5mm C Ij: '? l ,\ * To

, : ... -~~' or ...

-oj.

(2) . ,R~mred parts.

No.

Description

-s«:

Qty.

1

2 3,

:;: .

,~ ·;·.';];·U]5;KE 1351

13011-KE051 " . .1310j"KED51,

.B.asket; 'CyLinder head Ring set, piston Piston w/pin

4 4

: ,< •• ,

(3) Assembling standards.

-
Jft § I .7.,f-;; .I~- 'Y
S. T. D
Item Sports parts
. "1:::07.. }'/, '7 I) 7'7 /'7.. 0.O6~O.08 O.O3~0.05
mm
Piston clearance I -".

. .;7.- ~ - OJ .J-f - ';1 . Sports parts

13

Item

I) :.-- f c I) /' '7'i~T ?: r", I I I . I

Clearancebetweenring& mm; 0.02~0.04. 0.015-0.06 0.03-0.07 0.02-0.06 0.015-0.06

ring grU(~>:·e . iiI ! -,---,--1

~pc~aran:e 2; fllimm i 0.15-0.351 .1' 0.20~0.90 O.15~0.35 r i 0.20-0.90

~-2

2

PISTON & PISTON RINGS '

. .. ~-'- ," ~;..: .. , ;- -_ ~

7..7-:; IT

';;1) /9"7'"0 f'''V');f-I)/7·}]OI~ j\Jt.-/':--- r (l) 1Li I') d1l Cl)jl~iEJ,HH.t Ii c·li: C'~€ L 'i t 'T'HiH -1/ tiftiE ~ ;~'i;ill" ~ g1:iE L -r J-; i) ;J: To

STAGE II

Besides the. boring of" the cylind.er .biock and

correction of. the' VB Ive seats contactirm surfaces" parts have been established which are.capaole for assernbfinq almost. without any mod lfication.

1::°.7.. f-.. ;:...- & t:".7.. f-.. ;:...- I) :"" ,~/ W:·· :3; li"j[ j! '" ~'. ' ,

1. PISTON & PISTON RINGS

~, . ,--.;. .(1) Main modif.icat;oJ1S,

a. 1::::';;" r /

;f-/{-+T1' ;(3mm (781) C L, tlFaiil:_a--1261.

;:' ,,. ,,- , -c, ~ ";_,,:, ...

a, Piston

The oversize ~ 3 mm (78¢). with. the dis.. placement of1 ,261 cC,"

. b. Piston rings

Two compression rings with the thickness of 1 mm are utilized,

The oil ring is of three-piece type with the thickness of 2.5 rnrn.

. b. r:: j: r X: .1) :/ 7'

;:J '; /V '/:-- .~ / I} / :7.'~ti. 2t 1 mm ~ 2 *f.i:ffi

.. L v • t l' )~ I} ;,; :7'I.t 7.. '1 ,;,:, k'~--:- A -7 -1 7' c L, .'-,

.... . -

J!I. ~ l.t 2. 5mm C ~ -") -r p ;£: -t 0

No.

Part No.

,:. Description

Otv,

2 3

111 )5- K E.D03 r: "'l-30n;t::::E052 13101-KE052

_ ,~asket, .. cylinder head " Ring set ;piston Piston w/pin

4 4

(3) Assembling standards.

tJi: § ;J.._i'-';;/~-';; S. T. 0
Item Sports parts
l::::';J.._ r:"- :I I) 7"7:;';J.._ mm I 0.07-0.10 0.03-0,05
Piston clearance . ~ . . _".

.. ' :J..;f.- '/ I"...,... '/ I
Sports parts S. T. D
r,U § .::1 >71.--- ?Y.3 > 1)/ :7- • .'::1 .» 7v ':J.:"" :1' }' I) / 'l-
Item ';;f l' Iv'lj /" 7" .. :t1 J[" I) .> ;7
., Compression rings Compression 'ring's
" '--
'. 011 ring"·· .. · Oil ring
No.1 No,2 No.1 No, 2
,
I) ;,; ;7c I) :/ 7'~-t ~ ra'l mrn 0.02-0.04 0.015-0.06 0,03-0.07 0.02-0.06 0,015-0,05
Clearance between ring & ring
groove . "
/.).. D -t .~ r,., I !
p 0.20-0.90 0.015-0.35' 0.20-0"90
Gap clearance mm I 0.15-0.35 I ..dz·{·-4 3l<:-

VAL VE MECHANISM'

.. ~ ,. '-,'

'2.' VALVE MECHANISM (1). Main modifications.

2 ltl#*fI#!i ( 1) :t iJ JiJ!

a.iJ J.,.y~ 7 r ,~ "

! -{ )1.> "/.1 >i' ~. /" 7' ~~£ T -5t;;,¥J,-v.·~7 C1 7 ., n~ ~£ L -c J) I'J ;t 1" 0

B. •. -Carnshaft

. The:r,ev.jse·ttbav.alve.:timiIl,g~',the cam -prefiJes-are

revised.

b. /{JV7

olt!.J1' ~ 111 -* a: IoJ 1:. i~:-lhH: 11'J, l' /" T - 7"& Tf -'~'f '/ - A l- J)~J{ Iv 7~~£ a: * ~ < l -r J) IJ ;t

-"'-to

-·'~:'·{:T;.)V·cr.·A:·"j") -) J"

-+r- :;./ /" fll1JJ.to) t::.liJ, '/ /" ;l )v 7, 7' IJ /" ·f 1.1'

is 5"jil; 7,7"1) /" f 2:: L, l!XftWfID:. a: 't'~ L l . : J;,~IJ.*c·T ,,"

. ·'i.;·~_.a:: i:,,;J;!;7'7'j'·'r:;"''f''rT~ 7/k ty:;r7"J~;:"':7'/ - •. ~ ;-_:",' " ·.'7,)'tt- 7' A -j'IJ >f ~ '/ /" f Iv I)' ?) 'f 7' Iv r: ~~

.0-':.1-"

b. Valves

To improve the intake and exhaust efficiencv, the head diameters :of-lbe:.intakB .. and .exhausr valves havebeeruentarqed.

~ :"

C. Valve springs.

To prevent surging, revised from sinqlevto.dual .spcin.gsand JhJ:1-irutaHedJDBdj,srBvjsed. '; .

d. Valve spring -reta mer & spring seat,

Due to the. revision of the valve spri ngs from single. toouar. the retainer and .seat are nel}\}!Y established,

, y'lJ:..f::.}t.h./~).T~:-c:·-t & 1..fj - J-. ~ J'iJE c' -r ~IJ *T"

",(2)' Required parts .

-- 1

.13511:KfOO3

. · .. 'J;amshaft

. No,

,.1

C;c:t].j:01st,1;JrHJ51,.C:'c,,.i',eam:.;-tlaft .

~' . ,,' . " ,:' -'f _ "~. ;:~" .

~', 2" , .'. "1371T,KEi:)S'1' . 'Vahle; intake

. 3,.137J5,KE051 ," ( Valve-,exbaust,

4 5 6 7 8

. ""'cg-0501c4240'S "":Spi"'rn~"iompre5SiDn{outer)

90502·KE051 13734·KE051 13741KE051 9091 3·03005

Spring, compression (inner) . Seat, valve spring

. Retainer, valve spring Lock, valve spring retainer

~I,·". \-

4 4 8

8 8 8

16

·JJverJap 70° Overlap 66° ;., Heaadia.-37¢

',Headdia: 301' "0"

"0"

(3) *.IH>f1Ji1?.:& lH!j:M£~ , .. mr~cg~~ 1:~lf-5 0

(3) Assemblingp(ol:~dl!res &: assembling sta ndards, Beptace with; t.I:Je.aoo,oJe.pans,

4

INTAKE & EXHAUST SYSTEM

':3.' (1).

INTAKE & EXHA'USTSVSrENlS;;;~

(1) ::E;oJ: j£~

a. -{ /'7"- -7? =;f; -}v F

+ -t 7' l> - -9 A 0 .j J-. )1.-- T 7 i'I I: # it, ;f, - ~

Main modifications.' a.,·lntake. manifold.

.;·Matched . witK·-the·: carburetor <thr ott!e bore,

~ trl:* L ~if} ;~1~tf[0)~' ,~ ~ ~ S CY;,: -w:~~!' L -r J-) q :;: ~t o

eniarged .. the', .ports.to.reducethe .intake

.. v .;'.' resists n ce.i ' " .

b. .I. _;f '/ -;z r"7 = ;f; -)1" ~' %~~~~L.m~~$~~~~itT~g*~c

b. Exhaust manifold.

Revised·' the': shape."tD- improve the "exhaust .' ::;,efficiency ", >

(2) Required parts.

Paft No: .

DescrIption

!

Oty

.".1" .. : '::''2 3 4

:·17104·KP751 .·19l:1j ,·KED5l 2191,-TE001 21912-TE001

.' .Manifoid sub.assv exhaust

Manitold-'sob"assy intake . ,

Gasket, carburetor

lnsularor. carburetor heat

,,-

8 4

40¢ 40¢

~--: .. -i:' '_.,

c (3) :;.;;--A~Emlrlmg,pr()'cedures. ' .:;·~:Rep'lace w ith.<the'above parts.

-':-".

...• ~ .

FUEL SYSTEM & Ace. LINKAGE

5

4 ~n~ili J.i_7.J. ? 7 t J1- L;i -'$1IJ> 7 (I) I~:3£~

a. ~-t7'v-)'

~D7~~¥7~~~~L. ~~~fl~~L~ f±t,* r: vr.1) fJ ;!: -t 0

b. 7;7 -t }v t- -)' I) :,- ;7 ~1'f\..-·-)'0)3t9:.t:ffp. I} /;70)1f3;f;R:a:~ 'c. "~' l,. 'r .1) I} :t t-,o

(2) j!,,~gs~

"4. ". FUEL SYSTEM & AtCEtERATOR LiN.KAGE (1) Main modifications.

a. Carburetor.'

Revised tlie.:thruWs·bore-:to matchthe specifl-

. ',,' .r:atiOn<f:or highspeed'cir.;iv·ing;

b. Accelerator linkage.

Due to the revision of:th~L:carbuTetor, the . shape of the llnkage.isrevised

(2) Required parts .

, . Description

... OW.

.Bernark

~. Cerburetorset

; Dellorto .

D.HLA40 x 2

·2 -__ ';73.o22-KEO.o2.... ...• ,.1.inkage.set,.accelerator

~ (3) Assembling procedures.

Replace with the above parts.

(3) lEliinj:ft

,", ".,.

',f""

..' ~

6

CY:Ul'mEBHEAD

-RACING ENGINE ASSEMBLY (:1~29-3cc) .

,.~,:: ,

""r

".; _. '~'--

~. -r~' -:; :

Fig. 1

:,7(7-:;: ill

,-'1-' ~':!./'9:;v!i~;~'Y-~-<:;-

---STAGE III

,'. ::,_~-:~·j~"-~:l.c~;;~~CnfjIUIER_H£An (1) Main modifications.

EniaLgeo,the _ intake~.ao:d exhaust _ ports:,to. improve :~" -,cc'!he'i n"takeandie:i:hausti-e-tficiency .

'Also, due to -thB,'revisionof the valves and valve '..- springs,-machineci the valve spring seats portions and inserted the valve seat rings and valve guides,

Xl')V 7', 1\ JV7 A -;' I) /7- O)Ilt'~':f¥p, -1\)1< '-7'.7, -;'1) / f'j - HWO)f,!!tf~tJDI&LfI\)V/'j - Ic-"IJ'/''7-~'/'<)V 7·:lf1 r 0) A ~ ~ t. i To

, L' .. ~

CYLINDER HEAD

7

. Ill:

Item.

§

014=

. Detail

"i" ?!, .: f O)fth Size & etc.

Intake valve

jJ .Jj-ir~ll38.¢ ~ T.£.~6.~,j .

Head dia. stem dia.

.I. or '/ - A r ri"Jt,. 7' Exhaust valve

I Pli'£6.6, ..

I Bore . .].

··{EX. )j ' .. " L' ·.~··~6 ;6 :f~'~~' ~-~~~~~]

i

~----------------"---~-~I'

/ {)t,. 7':'- - r- I) /' 7' (I ~T \:

1 ..... ) !

Valve seat ring i

_. ~~ __ ~~ .~~---~ __ l--~--.-. _. . ~. __ .. _. _

I .

.. ·(EX.):

/")1.--7""'.1 L'·7·'·/ Of ~ . i

. Ii -I" . - ~ U ~.)'

Valve guide bushing .

I X~

! Replaced

+ -:- ~ ... __ .;_ .. _. , __ . _ .. :. , , .. .1..::

I<!!.- 7' i ;tl). /fY·,~ r .: :i'll ~ tDT i +f 7' 'i. Ii.\( fij"~D J~

. I~ . _~ _.:

":... Valve . .sprjlJ@.~a1: portion Machined·; 'Recess machining' .

. ''''' .+-,.:_.."..:-- '. - ::____------------1

~-r~~ l~*m.

,-

Port shape I Grinding for enlarging

~-------------------,------~

~13't~%tk I ~*f.~Jr

I ~

.Cornbustion chamber shape I I Capacity revised

,', ,'J ~"-"l ;","-"-.iJ".:""""'~~''i'." • .-.......---~-...;...,. ...... --_,..:.---~ ...... --~--------_,

@

"'':~!'';:;i=~~:::')''''''~''~'~~:-~:j't!;~:,:

.. .,' sr.i.l}ch!l9 of the t;Y,I.if!?er block to~ 'Suff:~.~e.

~~: ->'~~' .;~-", -; -:-_ -: .,.~~ .~~ r . •

""~(mfef "1'o:c'jtindet'blot:kpar<l_gtaph. ~

: .. ~.

No.

Part 1'10.

-~I' .

....

..

:'.',. -_-,' '" ~~ ..

.)

(2) Required parts.

DesCI"ipt)on

Otv.

Remark

Headassv. cvlirider

-.' _~. 2 :> • .' , :-:.rn 15:X.E003·· ",Gasket, 'cyfimj-er .head

3 11 ql-KE002 Seat, intake valve

4

5 .:6.<.

111 35- K E 002 11121-KE001 U.125~KEOOl

.. 7' ;5 90520;12049'

. Be' ._90116-KEOO i .

,_-.9' .' '.:~ ":'9011 !):,K EU02

Seat, exhaust valve Bushing, valve guide (IN) .:Busni.ng.,.vaive guide (EX) :. :~Rjng.;,.shaft 'snap

.Boll, stud

. 'BoLt;st.ud·

r' 4 4 4

4 ..8 2 6

".0"

8

CYllNDERi'~~EAD

'l=ig. 2, •

:"-.t;',"

/'; )1; 7" :fJ' 1 F 7' '/ :y .iX,-~ '1 J: :/':9'/s>"~; ft.." -. <. M'i.l6{'t O.018-0.035mm (20·C)

(3) Machining procedures & assembling standards ..

a. Valve guil,'le busbing,.r.epijlcemeE1t .. , .... :~. ).;;,;<:~,

D u~ .' t~t he ~ ~~:vf~l;6~~'of th'&;~'t~~'~~~ .d,f~rrie~~r /~

t he valve ."guide:iS. revrsecYo·.wftt:1' ·.a·small er'- :bote ;., f6':o@} j't.em. .' <.'-c:'", ,,;, .. ..' ._:C·

Valve guide bushing x cylinder head

Fitting allowance - 0.018 - 0,035 mm (20°C)

(3) 1JOI1J)ti~ LffJl.ti¥C~

a. / \' )1; 7·:fJ-.-( F 7' -y :y .:I- A. 'M'

"

/.;)[_, 7' :fJ".-( F Ij: r{ Jl;7~AT Al1C')-g[1f,':: 1*U.

7\ffC')+~pto) U;.6.¢ }·t:~~L.;tTo.':,

@ ,,~~:~~~:t~~1J;;HM~~"I:~_C

TI :r,,~·,~"7' ·,.)i :1±1~'l!.<C,clk:U.', ""·~}l.£i,tl..l;t;·t} H . ....... " X1!ltllJ(. . ,:; ·;4 . .::I'.Y::I=;':b, •• P'< v •. ,_cfffl':

- 7' 1= '"(1$ lE'9 {i '0

Caution:

Toe: . rept'actmu:!nfoftne.,:vilve"guJift &isbl~;;" must accti'rn to tti.e. repak.mannatprac.edures}·:

" - . '. i

':"', , •. " of th'e,~oon.venti~tiar',elTgin~~:;~', Alsa;" a1-iltr

replacement, inspect the bushing bore and correct with a reamer if found defective.

b , /, )!'-7_;').-:-' ~I) / 7' A~J' '. :'.: -. ",.

/')1;7'ffO)$[~1:1fp, -1 /7--7 &'Lf~'f I' - -AI-- 0):/ - ~ I) /7'0) A tH: LiT c

:/ 1) './ _l}(I'....'/ ~ .. a: *~130· C,:.:1Jn~A L, ! -: }[_,f:'-'. - I-- I) ~ 7' a: F -7 -{ 7.{ A (: -Ui~·i:r.4x,f.ta 2: -trw; ELiTo

! \' I[_, 7' :/ - ~ I) /' 7- li.{ :..-- T - 7 a:.:r. 'f '/ - A I-- J: r; 1 mmft&m~{~IJcl:J:', LiT 0(Fig-3-a,b$

bue to'tiie:i:eVision of the valve-head.stiametery" replace the intake and exhaust seat rings, Heat·the, cylinder head to about 130°C, cool the valve seat ring With dry ice to shrink and fit.

The intake valve seat ring must protrude into the combustion chamber 1 mm more than the exhaust .. (Refer to i=ig. 31 & 3,b..)

:/ I)_ /' 1/1'... 'y. F X /;()v.-:;ti/_·!:- I) >' 7- M\.!i)(t O.07±Q·Olrnrn

Cylinder ~d ~ valvesear'ring

Fitting allowance - 0.07 ± 0.01 mm.

CYLINDER HEAD

~ - I- I) '/7' c. .:;.... I) '/ ':i",·'j f t Cl)fl'lj ,;: "9 ~ re1 tJ~ l:iBj;E t: 'J, ~Hi) ,;: A. 0 ~ 1,..' J: oj ~:'+23-I;:~i~"9 .Q 0

. c·;:.; . -.

Caution:

.. -':' Sufficient care must be takensovthat there

is noiclearance between the seat;'rjng and ;, ·~the.";cyl~i1del'·,.blocki!ond.;-aisofor 'inclination,

. . . ," . .": . ~ ."::: .~:.". .:.:.

of the ring.

.\ .-'->

STD valve spring seat surface SDT/~)II"fs/1I: :,.,- ~rnJ

10.9 (3K) ; '-'28",~i 9.5 (3K.8Ji.....__341l>_,J

;1:·, •. ··

Fi.g.3·b

,....',1.'.,~..,~; if!i.'~.· 00 ~ f!

Contact surface angle

45'

'\- .

65'

! , 0 ?

mm i 1.2::: 0"

~ i') ~ffi ,___I_n_ta_k_e -'--f! -------1

Contact width

.I. q. 'f - A. l- mm il' 1. 2 ~~ 2 Exhaust

1/7-7

c ,}'{ )v7'::;v;:f 1) ./ )' "-' - l- gB nD I

/ , )l-- 7' ;z., 7' 1) / 7' Y - r lW (: S. T, 00 H iii J: I) 1. 3mm O)f7' IJ 1JaI1:- L ;I; To

. (Fig-3-a, 3-b *¥,~)

c. Valve spring seat portion machining.

Machine the valve spring portion 1.3 mm for recess from the standard surface. (Refer to Fig., 3-a & 3-b..)

d, .;f-- 'FfflM 1'/7'"-7

····S·:T :'DWi;~~i*Blilf~ ~ B':: ~ ],}'f! 0

. d. Portgrmding_ .·.lntake.

.'_ Perform' "the ·~grinding .. by··maintaining the standard, shape.

~ .. ..

10

CYLINDER HEAD

/ .... '

Ii!;!!,".' .. '

Fig. 4

..T.=\'-I-7 ~

Fig. 3-b (7)~4*;lHt~O)tJJllilj, ~]f~ ~ :b-::.:(;:,,:t To

Exhaust .

Grind the oblique lines of the Fig. 3-b.

e. ~13't*:!.JaI'& If y I) "/17-""J ~'lID~]f IY

iM.1SE *7f;~k~-~~ 'j'- ~. :CfPlw.f'!::' ,~}± wrlt~wr]~ 3 -,c,. >-ll.Se ~'':; 1: -j !: y I) "/7"/'- -J F(7)*iIDfijf~

a: Li +,

, .

....

,{. f.):-· / (- ~~:.

-c

.•...

,~ ',

-, >t~· ~,

. ,_; ':.~. .

L,"

;',.:'.

e, Combustion chamber machining & cvlinder ; head.surface. grindin-g.

When revising the combustion chamber shape, surface -grind -thB'_cYhndec,head.;surf?C£L,SO obtai'n the: compression, rari:o ·af:;1(3;,.j;l5'af;

the- same-time:

A~A Sectional view A-Alf.i>

. \.- -:

\

re,~t~~Of cvlioder ~

/

Fig.5

CYLINDER HEAD 11

:1~!'di'E*~fJ Combustion chamber capacity ,

JtftBif 22-23cc As a unit - 22 ~ 23 cc

*JHt~ 31cc When assembled - 31 cc

. ~ . '

f. Water jacket rnachininq .

Depending on the grinding volume 'of the cylinder head, warp<l;_ge may' beproduced fr,om heat and instatlation :' ot- .tha ,:cylinder head.,

:~: -~ ' .. ~:

'l ') :.,. '/" ''I rffi] <TJ Iiffiff.ITt (: J; -::i T'!;!: 11& r./:;, 'J :,... -1'A,,~'1 H')t.%~rt;t~: J:. I'J (fT';'" tli'i\ ~:: . " ',., "c t ilJ1f:-- :: <TJMifU:: L T :". ') :,... -r,,'Z 1":00 3;.

PJflUi" ~ Mr:'ry iC-''771'7 ,;_;-} gflr::: 7!1t:1':"?fi:iUDIi"oeL iJo (Fig-5 ~~~)

" 'gJ ,

.. " ""

. ~ .

To countermeasure "this, perform the argon welding on the water jacket before grinding the cylinder head surface. (Refer to Fig. 5,)

":,_ ,Caution:

.: A:fter"machining the b;;c 'and, a, perform

, the 'water' test: ,for"S -- ,10 .. minutes at 2 kg/cm2•

, e,. e , ~':' '11):g. ~Ii'I 1f: 2 kitcnlt:'"'( 5--'ltl5T ' M*L±T:A ~ ~+rt.;.:; 0

g . 0 ';177 - -tj-;f- - ,,-1:,/ ,,;f-)v " O))(~

a ''/ fJ ~ +j- # - " ±: ''I rf. JL,- j., (~09lG-1n005 r- -X'6 :'-90116:08127X 2-) 11 ;,r.\r~,¥" -;- r@li, , '/ il3l7)tJ!HI~~Jill::'T'-~ t.:: &') .. -(1). ,])0'),7';' '') ,._. '-"To JLt,} t: £~ 1., ;:.,To:

g. Replacement of rocker support securing bolts.

TDprev.ent;.:di~m.agjng of" the .cvlinder head threads ," reP,~ce-, :''the' .rocksrzsuppert seC\JT in 9 , bolts r900T&'lJTtJ05x 5; 9011:6;08127 x 2) to

.:~T '. " .,

, , ', T7.) ,'fa) stud bolts,

• ,'.: I~

'f

~. I

12

CYLINDER BLOCK

2 ::;~'~}'::,;..:i:7' D .:; ? ( 1) ::E ~ jfJ!

l~ " CY.LJNUER BLOCK (1) Main>"modifications.

Increased the cylinder bore from 75¢ to 791>, (displacement from 1,166 -+ 1,293 eel, grind the cylinder block. top surtacewith a surface. grinder, .

:/ ') :,. 7-0'7 a- 75 t> 1.;,',G 79:1' I: -tt-1·A T", :/' L f ~,;f. tIH'tM1l66cc-+1293cc:) y I} ;, 1'7-0 "/ '7 _tffij;i-lJ.) Iljlj liff)g L J: -:to

(2.) Required part.

No,

Part Nn;',

Description

Qty .. '<

,'1495-SP001·

Plate plug (fuel pump hole)

(3L' DUTh;E:& litJHi ~~

a. _tffij :!;JJiJU liff ru

L'A I' :"O)l:::':"J:.'t?tO)~~':f'FP, ;_, 1):'- 5' 7" []') '7 .L mi 0) tlml] pJf i~~ a- tT P ;;: l' 0

(3) Machining procedu:res& ·assembtin~.standards:.::.·\,

a. Surface grind ing.

Due to the revision of the dimension above the. pin of the piston, surface grind the cylinder block top surface,

~- .

M
1:0'
"
t
'"
tri
00
~ v". ,

Y I) :;..- 5"7< [] '') '7 _tOO Cylinder block top surface

Warpage allowance - 0.02 mm

b. ;J{- IJ :;..- 7-1iDI y IJ :;..- Yff a-75, h> G 79 ij I: .fJtj;;:t ~ t.:~ ;y.I) :;"-7'&rJ*-;:_/7~1JQ,Ia-1T~':;:To"

y 1):/ Y1'Ht 7" P .;; 7 J:.oo J:: IJ 15mmiJ'0 nOmm 0) ra' (: j;,' r i ~ 7,7 ';7.. ~ 11 rDJO) ji + * ~r)f1l c L ;t To

';: .. :,,}

~ -, ": .

'·oF

b. Boring.

To enlarge the cylinder bore from 75¢ to 79¢, perform the boring and honing.

, "The' cylinder. bore, must be the minimum actual value of' thrust direction in reiationbetween 15 mmto 110 mm from the block top surface,

. CYLINDER BlOCK;'--: ,

13

.

~ .. ,- ".'f~ ",

r

~ 7\1 §. Item··' . ,,' .

;z..;f,-':; )~- ':; Sports parts

S._ T ... D

. I!;z.. r ::,.. 7 I) 7. :; ::,.. A

mm

Piston clearance- .

O.07-q.lO .

0.03-0.05

.-7

1 . I::'_A ,,' /1.l!;tm~ (20·. C) I::a t1',Q !:: X"f< .... ;Z; .. '.' ~-".~ijl~~.ro;r5.A~~~0§*.~

fiB t1" ,Q-a -

Caution:.- ..

1. The': piston diameter-:' must " bathe maximum actual value at7 mm abo'l!! the . piston skirt in. thrust: dir.ectiol1~' at. norma!1 temperature (20°·C).

2. After machining, perform the water test for 5 - 10 minutes at 2 kg/cm2•

2 hUI:fi~*l£T'A "-~fi"'o,- 2 ki/cnf 5 -1 01t

c. ;_., I} / 'j';z.. i; - !- ff~O) iIDIfI! t)

..L 77'7-1 / yx.ti-'(';z.. I) :W-e-;_, 1) :,... 5'7-. i;. H'$C7)iID1IXJ) (2-3C ) ~fTpi1'"o

c. Chamfering of cylinder 5k irt:

Chamfer the cylinder skirt with an air grinder or file (2 - 3")

d. Revise the bolts securing the oil fi Iter and alternator bracket and thread to M 1 D, P-1.25 to improve strength-

d. t-1~7{~,&a*~j*-777~'l~C7) Jti:ftff~C7)i;;t:J--2iHfi':':IU:MIO P-L25 'I:·. rlJe L, -~Iit ~ 1olJ: ~.-tt- * 1'" 0

. ~. 110,

. . ~., ..

. ~. .... .

14

PISTON & PISTO~J RINGS

3. (1)

PISTON & PISTON' RINGS Main modifications.

(1) :i: ij:l[~ a.k';z,I,/,

a. Piston

Revised the shape to provide. a flathead .... : .

b. Pistonrinqs.:

Will. utilize

a compression

ring with

the

*f~m L. :t -1 )v I) ,>f(;l:,7. I) - 1:::' - /. '9 l' -; c l, . ~,~·U.2: 5tiim',: .L :t"L t::::;,

thickness of 1 mm.

The all r ing.Tis, .ot_·:threecp[ece~ctxpe.:.;with: "the, thld;:;'ess of 25~m.

c. Piston pin.

c. t:;<' t- /' e:"/

1::::';<. t- /' \::'/'!HHI~18, J: ']20,o r=1[~ L, ~i}i ~ .±~. L T ~ f) :1:T 0, .r.. '

..

Revised the outer diameter of the p iston piD

from 1S¢ to 20¢ to, rmprove the.strenqth.

(2) Required parts .

No.

Part No.

. Desc"r'tpti on

,"..-,_.-

Otv,

2

13011-KE004 13011-KEQ06'"

Ring set. piston Pist6n::W!pin' ,

4

4 -."

', ..

.~;- !'.'

, . _~ c-). c--:>.

~ ~.

h. T_ •••• ". __

(3) *11 ft1i$,¥f (fm#~i1h,

a .1::::' A t- ,;~X '~ I) )' $'7'0 "J ;I O)!ri'@-

'i I) /' 7"f,70)'/')/:5'J:.iIDJ:iJ 15mm7J'GllOmm

. O)F,,' r: :to' it 9 7.. '7 7. t- J5 rDl 0) fi+ ~i!l.lJi~ c t:" A t-/~~-~.T$J:'J7_J:.$0)7..'77.t-$ rDlO).*~.~tO)~(;I077/,A) #*- 8 0) J:: j (: ;J: 9 J:: -5 (:1.§.ft (t ;I: To

(,/I) /' ;r-,tu "J :7 O)JJ'i:fllffi)

(3) Assembling procedures & assembiing_,standards.; , .~

a. Fitting of piston with the cylinder block .. ,

The minimum actual. value of the cylinder bore in relation to the thrust direction at between

15 - 110 mmfrom the cylinder-top surface and .the .difterence(clearance) with'.: the rnaxunuravactual value above 7 mm +rornthe end of ·the piston skirt in thrust-direction must accord to .the List 8 upon assemb lv. (Refer to cyiinder block paraarapn.)

~- ,

- '-'_ -" _'"'_ '.._.. -

PISTON. & PISTON, RINGS,

t5

r]'{ § I 7.;F- ':'; /{- ';I
!
.,Item·.",,, .. \, .- S po rts pa rts
~. 7. f... ;.,;.·~*fI 78.96 +0.02
mID
Piston standard diameter " -0
e'7. I- /;7 1) 7 '7/7. 0.07-0,10
Piston.elearance mm _ ~ _

b. Weight" difference-o+pistorrsr: :~,

The~'we,ight 'difference -o+: each' per one'. "un if' (including piston pin) must be within 2 grams.

c., Piston pin.

Heat the piston to 80°C in oil and further chamfer the end surface.oftaepia-with.arroit stone to smoothen ther:df)sef,t:'care:tu'llywithO:u1'~ scratching the corresponding part.

1 is: ~ t)0]1}4qyig:!i~: {tSj.}~ c- e /~'~t")·

,.

(12 g nl*J eli: To

c. 1:::' 7. r / t::' /

t:::' 7. I- /' i" iEllf'i? t: T 80· C r: ilfr.1J, fr:J t::' 7. l/' ~'/' O)jffijoo i" iEllliJJ:pJ.:,-ctlfG ~J?\':~~~ J::._7-00 JV<:i') L, .frtt~i:I~i"--:J't~pJ:71i~;~< f-) A. L i: To

; -'--r-'

• 1, "; "

<',

1:::7. r ~ 1::' /' G!) 7Hl mm i 20ct~,:~~ ..

. ,Plston pm Ol:Lter drame!eri- '-"'. "'f ",,'~'.' _; ',::.

" ._:-' -r- " :5".

r]'{ Item

§

I 7.;J;- ')' J~- ';I 1 Sports parts

~.t::'J,. r /v)I:::~::r :r.:::tf';~~:1 _20:~~ow."~' ~.: <,.

Piston pirr bore i

<

} -: :;:

., .' @:,.,~.' " ..'. . .. : . ,.,",-, : .

I:::"A " ;; C: 1::" Xr-/,~/·t:~-ff'i·t:"X '_'?, D''" .. ," . 80· c. ili:OJaif~: t::":/ fr m-C'¥f! 1660 ~ flEJ3Uiilllt -eTo

Cautionc-. _-:. " tt R"mfSfcitt6riwhe"tfre·pinC31'Hfe.·PUS"hed·~< into the piston with the thumb at ao''c.

~-9

b. f-:'.7.,.~>')/'7·

d. Piston rings.

··f

;

7;f--')J{--; Sports parts

Ts. T. D.

'Gap clearance-

mm:

o 15-t).35

0.20.-0,90

.O,lS-0,35

0..15-0..35

0.20-0.90

I

~;e:ra~~~ b'1.t~e?~':::~'e.~l~g:~mm). 0..02-0 .. 04. O,015~Q':O~,.\ Q. Q.3,,"n:~o7;) O,,[\2,~O.,.06, .~'.l.L Ol'5~Cl.06

. r00\1e:' . '."_ '. . .~:;. ~";:",:,!~?- ;: _

. '.' . 9 .• .: ,.'- .... ; ~ : c:_':':"_",:_' i: _:__"--iL' --'- __ -......,~+~---'-----'-_. __ --.,-----_-_.~_~,..;..-~' . ._ .. __ .

:;}O :t ~'i1~ "-

Item

~-10

::r.:/~7' v 'Y '/'3 :/ I) :/ 70)~*ruH1 ,/I} >-'j*lil:~ . ~M'.£ .. 't ~ t.:d.l, '~7jlHiJ;:r7it:fr1.J' ~:'im]& ~H~, *-Ii it It {>o .

Caution:

To prevent vertical scratching of the cylinder . bore with the compression ring ends, assemble after chamfering smoothly with an

16

CONNECTING ROD, CR~NK~HAFT & flYWHEEl

4 :::J * ? T l' ;.-- ·~;t [].y ".. .:

? '7 ;.-- ? ~ l' 7 " & 7 71 *--{ ··;~·:;v

4_ CONNECTING ROD, CRANKSHAFT & flYWHEEL

J1r~~$E!i!;.·~-~ a - -:3 _:f, Cl 7-1 / If [1 'J F

t~~ ~.~ 1fJ!, i., oot?.. ~a:'IcT±"$ -tt,('J)t) ;t:,;:r,;'. x, +~~mt;:7'·;i:"';L.L. .. <~,5'·1'7'I:Vrh't)'i.

, "~ , .

(1 )

Main modifications. a. Con;necting rod,

...

b. 177/7:"'1;7 J-

;t -1 )1;17 I) 7 7 / A .& rJ If -1 T ~ 'J 17 J {7 / A a:~lJiTo

Re.",,'tsed .. ~he",malariaJ.to..impro)le:th.e'OurabHity, Also, the small end is of less bushing type,

b. Crankshaft.

.: " ?jL cleara~ce_·is· pmv.iged and d:'Sln~_mic batanCfog", has been performed.

c. Flywheel.

,

Lightened the weight and dynamic balancing

has been performed,

C·771*1-)\..·

!l!:fI!(T)~~& rf 1/.1 T ~ ,/17 J{ 7/ A a:.i1X Ij i -f 0

(2) Required parts.

No; .

Part No.

. Description

Otv . .4.,'- 6

Remark

':',

. "

2

. 1320r-KI:OOr 90105-1 003D

Rod sub-assv. ,connecting":, Bolt, flywheel set

"0"

.....

';": "

, '

.,

. . F

"

v ,

, .' , ,

0,

d')'/ i&11:t')~a~' ~.i1~.~'~: -.

(3)

a.. :3 -i, '7 T l' ;;, ;'--O';;i J-' . -

1;::" A J- / 1;::. /' C (7) 1Jl7.-@-I;l: 1:::'7, " / r::" / I: * l' )L~ W: t)'~-; 1itlM..1"~I: of ? Anf8:'.* r·jl ~ j nffJ

~L ......

~ ~ ~~ n{:Ii.5!: 1"1',0

a.t Connectirqrod, ' •.. '-' ,: .• ;,,'

For fitting the piston pin, apply oil onto the piston pin and it is excellent when it can be

.easily, inserted .at .normal temperature, _

~ .;: • ',:; r , • ...

'.
. .. r ".7.:¥~"J I'; _':; I ' '.
.1,: JJi[ § S, T. D
'. Item I SpDrt~ parts ,_ 1
-, I
. , .. " j .. I
::1~,;7 T 1 / ;7"0 'j to';j-{)I- to t,liit I- )t,:;7 < ~_[:: . .''' , 500 400-520
kg-em
Connecting rod bolt tightening torque I
t:'A r / 1;::""'/ C J _:f- 17 T 1 /17"0 'J r c (7)1' ~ re~ 0.009-0.014 0,004-0.008
mm
Clearance between pistonpin & connecting rod
.. -; .,
EtIl t) II,lUt (IOOrnmr:"?~.) -.
mm -0,.04 0.05
Bend limit (per 100 mm)
·f:l L: ilPR.¥ (JOOmml:,-? E: ) mm 0.04 0.15
Twist limit (per.lOO rnrn)- .. ~-Il

CONNECTING ROO', CRANKSHAFT II FLYWHEEl

11

h.77/7).--t71-

'. ' :; 't -7 1vms&: tf 7 '7 / 7 I! /$0) ~'I}'7 '7~/ '

7. a-ID~lH .. *1" e

b. Crankshaft,

Adjust the clearances of the journals and crankpins.

lJ'{ EI v-7.f±m ,I , S. T. D
Item Racing specification,
:; -t - -r Iv lilJ. iEtrt ~ rIO' ," I O.016"';:;ot040
mm 0.05-0.07
Journal oil clearance
:7 '7/ 71!>1iJl iElli"" ~ f'a' ,0,..04..-0.06 .. 0.024..:....0 .. 048
Crankpln oil clearance mill
.
.. "
",','
:;-t"--;-.iV~A'77. r1"~Fs'I mm 0.04-0.15 0.01-.,.0.222
Journal thrust clearance
:7 7' / ;7 'f 1"' ") 7<~1t r Iv :7 kg-em 600 540-660
Bearing, cap bolt tighten ing torque
~ 'fII ~ -, mm I 0.008 I 0,01:.: _
Roundness limit I
IiI3 t) ~~ ~ 0.02 I 0.03
rom
Bend limit ,
I ~-12

. '~"

c. Flywhee1:'

Discontinued the standard flywheel secu,ring bolt (90'lD5-0toQ'&) ,81:!d .Ioc]; plates' .and.wiU u~ilize (2)"(90105.'10030),

.crankshaft x ,flywheel

7 -7 l' ;J-; >1 -)(., -I: "J t-- ;t{ Iv l- :.t f~!$g~& (90105 -Ol005)&rfo ';J;7 7v-H:Jjfll:.L~~(9,Ol0:5 .'

·-10030)· ~(f}I:r·L"';;:;"-i;:o·'~':' ,,~'~' .,' --

7 "7 /.? ).- i" 7 I- X 7 '7 <I' ;J-;~1 - -)v ....

," . Mi:lt f JI:,-7 'So.tJkg-cm' - 'i:' ", ", , "

- .. _ .-

.,' ",'

" .~

'i,

Caution:

It is desirable to perlorm the dynamic balancing with the flywheel ,.and crankshatt 'asci unit and' the unbalancU;g yolu~e' ~~s~ be within 241-cm_'·-- ".,

, ,:1, ,',

"f1T~ ,;t-7/'i7/.A117'71;J;1'-JL-t-77::"-7~~7~i-~T~m~~~~ij~*L<. 7::"- 1'i"7 / A !lli 2 \j.-cmJ;), Pit.,:t ~ 0,

", ,

18

VALVE MECHANISM

',,--;,<,

-" :5. VAt VE'MECHANISM

._-: UJ _ -Main -mudifications.'

-a __ Camshaft.

/')1; 7-7'1 -'. /7- ,i; !-,7'D7-'f !!--~_'?t~ L -r ~lJi--to

The,val'Y'€ timing .arrd.cam.profiles, are:revised_

T_D_C_

B.D.C .

. .

Fig. 8

. - .~

-c-c' ." '~F i I
-- 4FmH¥J8.jM I [- 'J 7'-t;,.- 7'-'-
,.j
-: .. ' --. '" ' c~ ~T. - -" -.,,valve tim ing , ., '-):; J_,;t)7 l j-{-1t.; 7':7 I) 7 '7 /;7.. Cam top center
co
Part No. I Cam I itt Vaive clearance f
1 A B C D I E F
mm rom I
153 -I I N 0.35 I
13511- K EOOl 91 87 55 7.5 EX 106 109
.r : 0.3.8 I
-135_/70 1~~'l:35 . ,.LN : 0.35 ,
.:~~, __ '13511-K.EOO3 l I
- -, 7.4 " ,-110 ,j . 110:
""E X'-: 0,35 " r-
-
i I 861 ~_941'461 ,:r __ 1. N ;,0,3 I, :1
'- :_-:13511- K E005 j 54 I 7.2
- J06 .':H4~e
I __ "EX: 0.-4 - -
136 -~ 'I N.: 0.3 -I -f ' '.
13511-K E051 64 70 30 '6.8 ', 104 '}'10
EX : 0.3 I i ~-13

~,i

la;.

. O&:fj~*jjJ,¥O) ioJ 1:.& ,[f1tit iJIJ!l(CI) t: /I)',jfj~*, -;fii;~~~ t r hI') l: 'j-o

b. Valves .

To improve the intake and exhaust efficiency' and to I ighten the weight, revised the shape and dimension.

6.6

8

Item

..

LN.· E.X IN

29

iJ4j-miii' " Head diameter ..

mm

A T J..~11 Stem diameter

6.6

mm

8

«:.,.....;.--

~VeraIJle:gth .•• ". rnm I ;{)'-'7'"",/ FD:J/'JplV! I Head thickness limit mm I

95.8

0.51

~-14

ioe.i

100.1

0.9

0.8

c. ;{)v 7' A :t I) /' '7

.I~,>4, ,." O'l~~{t::cti;Pt~.,; ,·y;:,,-.'7"'}!<';:\Tf1":i' 7"." . fJ';.; 7"7' IVA 7°1} /' ;7' (: 1I~ L l' j) f) g: To

c.' Valve springs ..

.... Fc,r:+ifgf( . p~rtoriniiri:ci;;of:;ihe.':<engrne,·revj'sea "~) the valve springs from single to dual type.'

____ ~~ __ ....... ~-;- ~.;_;;_.-:._~_""' ...... '~"_'- ;',-,--,,' '-;-' , ~-~\<"~'~~;'; __ ~ :', ..... _._·_.i

I

~-~·~ffi~.-~·-' --~~~~--~--~--~.~

mm III 41.8

Free length

--.~--------------~-----~----~----------~

lrXl'J{ t :& !

mm I ostal led lencth

J~ §

Item'

7"77 Outer

38

1/T Inner

32

IR V) f'r fi1f~

I nstalled load

16

.. _----_ .. _.- - ,-- -----.----------~------------------I

kg

fif7b~t~

Effective windings'

7.

!

.I." .5.,8

4.2

Coil wire diameter

-----------------------~-------

if±S]::1 l' H,.. 11

mm

mm Average coil-d iarneter

28

~-15

I

,

2.6

18.4

20

1',,-

.' ilALVE MECHANISM

d , / ( II- 7' A' -;" 1)/ 7' I) T - -j-

'/7' 11- A 7" I) / JAm I:ff;i~a-~lt~ L. Tit "J iTo

d. Valve spring retainer.

Revised the shape for dual spring type.

e. Valve stem pad.

To maintain contact surface 'with -therocker arm, the. pad will be utilized, ..

f. Hockersupport.:

Due to the revision of the valve length;.provided an addition machining or) the ; standard 'part.

e. /')l./;J.,T.t../~"') r

o :) f.1.- T-.t.. 0) .§if) iID ftlo)liEr~~7) i: ¢> /e';I r' i-ftffll *1'0

f. 0·, 7J -;iT ;f, - l-

I {)I.- 7":if 0) ~£.I :"t.1) ,,, .m;$ft~crD[:m t.lUI.2: lilli. LiTo

g. Rocker' arm spacer.

g. 0 ·:;t;-7-.t..AX,--t]-

~o 'J 1; ~7-.t..rB'O)A -;"1) / 7"a-7,1"'~--t]-r: x~L, m:tJta-~ye:1.t;!:'T6.

The spring between the rocker arm' is replaced.

"

h. -;,"'):,....::c. D ';I r'

Uiit it 0) t: 3? H'R a-:;r~ L T t;, fJ i T e

with the spacer to reduce theresistance.

h. Push-rod.',

To lighten~'the material-is revised ..

.':'

J. ! \ )(. 7"' I) 7 '7

tm~.g~JtI:*1JDI a- L, U:!l'tft T ~ :. C iJ[~;!;

I. Valve lifter.

Provided an additional machining

on the

. . ~ ..

standard part for desirable lightening ... Timing gear (for camshaft).

... ;

" . ~~.'

P"r·ovided· with -7 dowel pin holeS'. tor easy

j. '7 -1 ~ :;'-;7- ;:f-t" (7J s: :,... 1'" 7 r If!)

/ .. ; J ~e;..- fL a- 7 "")- C L, fJ.t.. ';/ ... 7 "(7) -1: .. ;

selection of the camshaft.

T ." /' ~: ~~:~.(;~ t~; ~ 'L i: rl ',' • I)

-:", ;

,. 'J

c-',:

,',"

:;'i

-.,- ~ .

v "

", 'k

.. ,'.

,21

. ''",i-''* =-::: 1= ~c~!J) V - A 1± t!.w 7. ;f - '/;{ _e>"j .~i'.·j-;'.3'5"'3 ,K~.X,]"\Y'·\i%:&rJ15;' >,f;Jt'~,*\~~~:'tt;e;"(~9" :a:: vc~) IJ iTo

fr~jHHUlj r:i$ C 'r: T;:L - z: /' ipq,§:~-JJ!1Rl··--CT ~v<~\;f1';,k'~:::_> 7~~ -ff"-jj-:J~giij:'~Jlt1:O)jE

•... , .....

. '~"

.~ ~

'. "., :J .-, ,;t ),Crp.,~_(ftiLtlOO:': ~ 0" @i m LJ.: ~H;o'1 ct r 3 5' MllE ~~.fo -C T Q

-. ~-L· <.. ..... ..-

':2·-V':~-~1&',~,(.tq)1-£:;;&:G"'"¥fHJ':.t;;:~'t'J:'l0'f~ t:t7r V) <"_f!. .~ (l" "

.... -.c3~,·'1i;!;;::~~;IlU-Q) 1 ~ 'tt5~ ::: -::n' 'c. ij:,;ci~jEI'B3 ,i1 i tSf:i.m L --r < t: ~ Po ~:4_",~ "'A:;Y":-:'j,l '-~_j iJTa.~· ::}t~ -t ~ t~g.I/}) fJ ;l':: -L

• The racing specification sports parts described here have been established by sufficiently maintaining the

:,.': _~~c,;':,~i"f,asj£i.'feat[U;e~LGf ~~To¥eiac~,~mSde,t'Bi'I§iRB:anrtr:i gtrt-;handzh'j\,e cal' _ . ' ..

~,_. .

, _, -: .• ,-, SeJect-1he, .tUlling"detaii_,fn"F!-C(i;-Br;~al'IG~'tO-.tb:e:tot:j~g.:re.gllJa1iDns_ .)AliJren..lryell.4ning :js:pe:rfo:rm:E!I:t,t~erlri\(jng on

;.~~ ... ?:. . '~~, ..

~pub1ic:roadsm1Jst :imti)-e per:f¢rmed.

. .' ~~~.

IF.- \' .. ~~.':':~ ~

Reference:

1.

The parts :cj.fl.dkated~j;I1~,-tA~~rerf1arILt:QJumfl'JJ,f ::th is, manual"iwLtrk1tle .:~IJ_-f '·;IJla".ksc,ilJdlwte:,,tbe.,-ganuine '. parts,

Always adhere to precautions upon handling and on assembling standards.

2. 3 .

Please utilize genuine parts when the parts are not specially specified.

. ·4.. . We reserve the right to mod ify the sports parts without notice.

-.

.. :. ~ ...

2 3. 4-

,5 6-"-

7

8

9

,1-d,

11 12 -. 13;, 14

VALVE MECHANISM¢-'-'

22

t311:5-KEa03":"_~::~ '" Valve., exhaust

9050 t - K E 00 1 '": Sprin g~ cornpressio n<'lo~1er(:, : , 9050ZeK EOOr " .. ,'. 'Spr.rl'lg;.cb rnpression (.inrrer)l\

(2) Required parts.

Description'

ow.

Remark

No.

Part No.

Rod sub-assv., valve push Valve, intake

8' 4 .4

',),& '0'

ff: 8

8

8

16

"0'·

13708-KE003' 13711-KE003,~:~,

,90Z0F24215" 13734-11 01 0 13741-KE002 90913·KE001

, 9007Zr 72661 .

Z 90072-72681 -

26908-K E005 26908-KE006

" I~ ••

, ....

- '~.

Seat; valve sprmqrouter) 0 Seat, valve spring (innerl Retainer, valve spring Lock, valve spring retainer

,. -. a -J-r_ :",.~,; ~, :_ .•• _~~'

Pad; retainer

-r-c :

Spacer, rocker arm No.2 Spacer, rocker arm NO.3

. 1

_j'" ..

Fig. 9

VALVE MECHANISM·

23

@

Caution :

,:',' ..

On theCamshaft$:'351'1.KEoO''f~r;d '13511- .~: .:' KEOO!;i,:asthe t:amf~,r drivingthefoel pump ">",,,is ;,.not ;,;.pro'ljded.,., ,;electric ' ... fueJ .,.'pOmp. ,is , .. adapted.

dJA,'l:~7. f.. cJ:3:SH-'K '£ j}Dl'J.tV:13511-K~E 005 I: i;t·7::L .,..,.IJ\.iff.). :t~tlim:1rt..iJ> -.:> I. \ -r I. ' f.J: l. \ t: d), flm'it 7:r - IiJ!i;F>.:t~ ~"9 ~ ,0

_,-', ~('.-. ,

. b. Valves.

.~ .. ". " .

,,' }.V7::!i,,:,.:]t'Cil:: ;17):iffrt "2;;fl,9(.~!$)

',' " . mm

; (j,LGleariinoebetween valve guide!specifi()d)

.. ~~----~~~~--~--~~--~+-----~_------

" " ( pIU~ ) II

mm

~;~ (limit)

.. ' JJj" ,13:'

Item'

I A;F-';lf{-';I 1 Sports parts

0.08

". :~~ .

7.:r.-A~l')m Face contact width

I 1.2+_°0,2

mm !

I

, .0.05

/\)1,- 7' AT£.. ~N;joo{~jH.N~ II

mm Valve stem end correction limit

0.5

~-16

(I,', :.

:~ 7 :.1::;_;'?-~ 'J ImJltH~pr~':)i~ t., ri)" -:f c}\ .:;_ ~. }1;-;j' $i~:b ,q,m,!J~i!"'~:L)lt~§' g-. 2,;: _c ,~

,~. ;

.;:Be-~ef1.ii;wtth:.t~da'Ce contact-surface and

'./·":"·"F~ci·,.coJtt3.Gt:;w_in(L:,tI'Ie<dressiTlg of the valve and valve seat must !)eperformed ':"., •. .s.uUicie.otly.

c. 0;; t; --tj-;f,- r

~~$cfo_( 13951-22010) 17) Tmi ~ WmJ L 't To

c. Rocker support.

Cut the bottom surface of the standard part

(13951·2201 0).

Fig. 11 r( Jt. 7' tJ .:/ f.J - -If if- - I- 1Il I ~ ~Ii

tr .;; t; - ::/ "I' 7 r ~ilI,l'.· C: 0 '" iJ - -tj-;f- - l- Too Parallelism limit of rocker shaft center and

17) if- ff & 0 . 03mm

rocker support. bottom surface - 0.03 rnrn.

24

"'''',

LUBRICATI.ON SYSTEM

d , -")1.-'" I) 7 '1

m.ilft~O)t.: 16, m~fr~~V')m~ a-"fj: <. L;I: To

d ... VaLlt,e::Vfter.

. To' lighten, reduceds the thickness of the standard part.

Lt'> o 60 T I

to

-----1-,..:

','1'

---~---- 45 -r --,-----.-;""~

. Fig. 12 I < lJ.. 7 t) 7 ~ JJil I. ~ ~.Q

6 ~jf~iI,:.~"

F .~ •. ,-'il" . ,~_. .

(1) =tci-1I:Y!" .:' :,' .

. . ~'.',

a. * -1 ))..:tr; '7 -,'

.m;$ gM'r:, i: :-gc~ L. £ 1" 0

It. LUBRIC.AHON S:YSTEM, , _,"

(1) Main modifications.

a. Oil pump.

Partial,ly revis.ed',the stanclagtr;1'8rt.' b .. Oil pan.

Due to up-r iqht positioning of the engine,

b. :oj- -1 JI.-/f:/

i> V' /O)~Jtftl:f-*p, tfHka-N:£ L. T ~ OJ

.... ' .. :-:;.

revised, theJibape .. : . •

c. Gil strainer.

Due to the revision of the oil pan. revised the, shape.

d ... OiFcoaling system.

Newly estab lished the camshaft driven'oil.co91.er. pump ..

c. t -1 }v;z, I- t- - T

* l' )v/~/O)OCJ!I:J: I), *~~*a:-g[£ l T ~ I) 1To

d. l' -1 )1.- '7 - I) > 7":"- ;z, T J.". ~k:..-~71-.~O)t-1~7-5-~~~a:-~ ~JE L 1 L t.:o

· 11321·KEOOL ',' Coversub-assv., timing chain Drive.set, oil pump

Cover, oil pump No.1 Hotor.ser-oil pump

- Cover:oj,I .. pump No_T' Ring,e"O"

No. -~. >,' Part No ..

. ...: ~- . ....:';:..,...;. _. .

15710-2601.0

2

3
4 .15115-KE001
'5 04151-KEQ01.
·6 15115:CKEOOZ: .,
7 90301-44049
8 91611-60650
9 90404-K 1"001
10
1-1 90405- K E 002
12 90401-12075
13 90430-12015
14
15 15100-24010
16 151 04-K E002
17 12101-KEOO2
121 01-K E003
f -; .
. ,' :;-=: ~"; "_ ,
~. -, .. ,- (2) Required parts.

Description

Otv,

Remark

Cooler assembly, oit

1 .: 1

For 3K-B ,

Bolt (for oil pump cover securing} Union

.1 ,1'

" 4

2 6 4 4 8

':'0'"

"0"

Ciampi ' .. Union

Union

Washer

.:,.

Hose, oil cooler

Pump assembly, oil

J>_

" 0" .

Strajner-s0b.assy:,oJI:·,·- .~:

Pan sub-assv, oil Pan sub-assy., oil

For 3K-B For 3K-H

Fig. 13

26

LUBRICATION SYSTEM

r

' ..

.u

(3) jJDIn~~ lft].tt£i1!

a. -t1'lv;f.':/7"

1) .) -7'{lv7A -r» :/ ~ (: .) .) -7'{1'v//

'7 f C7) rIM: ~ ~ 2 - 4'rn1ll0) ;/, i: ~ t ? A t., ~ffi II ~. 6 kg/em' (~~ 4 kg/em') t: l. ;l; To

;C 19n'f-4 fl' .I-:J.fllJ O).:L'/ :; /' O);ts~ I: (;I:: i::.-r 15100 ;-24010 ~ ftffll "( < t; ~ ~ 1 0

b. *" l'v 7 1 )v ?

3 K.:ffl <l560F33020)'Xt;l:. T; '2 Tffl (15600-

25010) -a-ftffll;l;To ~;t:,', 15600-25010· aftfflT~~ft:t1 )'v71 r'v~-777'') r (15. 609~2.401.o) .1:a@;q:'z,.~·c.1J; 1');1; :to

. "(Fig.1.4$~~)

(3) Machining procedures & assembling standards.

a. Oil pump.

Shim with the thickness of 2 - 4 mm is insertecLbetween the rei ief valve spring and relief. 'valve to maintain the oi! pressure at

. 2-

6 kg/cml, {standard 4 kg/tm '1.

. Also. with the engina prtor+ro April 1974,-

, .

please always utilize the. 15.1 00-2.4JOO._.·. ..'.'

b. Oil filter.

For 3K model, utilize (15601·331}20) or (15600-25100), for T and 2T models. When utilizipg1.560O,250J 0: modification is required+ on the oi I filter brack-et. (15609-24arO}._·

(Refer to Fig. 14)

I .. ~,----t.

Cut after welding

fiHJ W: \lJ ~Ij

Fig. 14

Caution:.

. If there is a bv·pass' insjde~ the 'filter';":it 15<;:.

desirable to utilize the 15600-25100. ,.,,,

As the front timing cover rear oil seal retainer shape differs from the 3K·H model engine (after April 1974) and 3K-B model. sufficient care should be taken upon installation and modification.

. . .

7,( )L,.~p;n::J~1' J~7..U)'~;Q: 1'5600-25010' ~B!

. m,t' ~ .:. c'fJf~ * L, I.. '0

S'K -.H~ J:::"'- V:'- (19741f,4 ~ J;l~) let 7 D::...-I- ~ l' ~ /?,~/~- 1)1':;t1' }~~-)!,. I)'T--j-- Cl)fl'~ ~#3K~B~cR~~~~. ~H. ~~~+~~

. ~ .... - ~ - - . .:" ..

INTAKE & EXHAUST SYSTEMS._., .. ~ .. ,

5\.1>;. ......

1. INTAKE & EXHAUST SYStEMS

(1) Main modifications.

a. Intake manifold.

It is of separate type from the exhaust, manifold and it is of alloy metal. " ,

The ports are also efltprfjed to- match the carburetor 'throttle, bOfe:""to r;edllce-,the intake resistance.

b. Ex.haust manifold.

To improve the exhaust'efficienCY,i! is of,

"

7 IJi~F~~i:I (I) ±1i~Sl!

a. 1';..- j- - ? 7 -=- * -)v F-

..:c.=\=-'/-A 1-7-=-*-)1" r<cl;t~j.~c L, ~ .g.:&~!: t, r ~ Y) ;I: -r"

:r--'-I- ~ ~ -t,"fv-;- (J)7. ti';J' r.Jv;k.T~I!: ~ 1± Tt47c,l_; ,,11)1 }'i.t1EtJt.*,iY tJ:- ('.VCJ) 1),';t;:T~

b . .:c.. =\=-./-,7. r7 .:::.*,_ It.-;F

4' -L'7"'1 9 .. ;17.J: t.. .. ~tlF rr.~.* ~ w 1: ~ <!± -c.t; : 1'), 4.i!m O(--40ffl) c 5i~ffl (T -50 ffl) IF ~'?iTo

4-2·1 type and for 4-speed(for K-40) and for

,

5-speed (for T-501, these are made available, ~

c. Manifold stay.

c , .. .::.;f; - II.- F ;Z T - 1'/j--7&U.:c..~'/-k~q=*-~F(J)~ WIJ!: f'f' \ . ' ~ 7'::' * -It.< f..:' rJ)IfXf;1' If! t: '1 -;}i!tii! ' , ' 7, T - 8:- ffl,~ l-r h I) ~'r 0

2) ~,~rul~
No .. Part No.
17118·KEOO1
2 1711 ':KEDO.E"·,
3 1}104-KP702 '~
r . ,
" n 1 04·KP7.03 _
4 17173-REOOl'
5 17173· K EOO2
'6 17177·KEOO1
7 17172.·K EDO 1
8 92J 32:4<:)820
9 92122·KEOOl
10 92122·41020., ..'
11 9213~·41 035 • - .. i'

Due~ to the_:'s~par,a.~iQ~;"ot"'the";·frrta-ke -and exhaust manifolds, the allov meta1 stays are prepared for installation of the man-ifolds.

(2) Required parts.

Description

Qty.

Remark.

Stay, manifold Martifo:ld',ji'i-rail::e:'j"-, .~' ':,' ','.

"",i ~

2',

Man, iteld SUb.aSS'f.._"e,Xhau,.'S, f - ":,' ':,. "j' .. '. " .

, " t' "'" ,~, ,Either one' '

Manifold sub:·ass"i".e~hau.s{ _ ;,:>,~.',,_ "", '

, Gaslfet. exhsust malTifdldNo. r .,;' 2

Gasket, exhaust manifold No,2

For 4-speed For 5-speoo c

Gasket, intake manifold

Gasket, manifold to .cvlinder head, ""., 8'0 It , stud

BDI1, sti.d

Bolt, stiJ.d> '

Bolt, stud

2 2 6

• v .. ~ "~'

";to'J';""

4. ;'"

2

"'0 '"

28

INTAKE & EXHAUST SYSTEMS

.......

-. ~ ~. "

~. :;..

80

l

I

I

®
l
I
I
@' . -
I .
~
.. I
<, I
'".
___ . '...1 CD

Fig. 15

1:/ 7' - 7 " .::. ;f< -)J., I' UsHiJL ;f - r (7) l;T.H'ilj ~JfH .. iT'P *' To

(3) . Ma chi ning . pntcedu,Ees &. assptn~l.ing:. sta_ nda~ds-. "

a. Intake manifold.

Grind the ports to match the size of the gaskets.

b. Exhaust manifold.

Grind the ports similar to-ths intake manifold ..

c. Manifold stay,

(3) j)DI1J;!);Z tfHH1¥.?!

a. 1 '/ 7 - 7 7'::' *' -)v F

;t; - r 'i if AT ./ l- rl)-k ~ ~ :: ii"it -r tJJt'iIJ Ii if itf 'd: L ;J: 1" e : ' .•.

, .... ,

b. ,I.k' -r - 7.,,\-'7::::;j; -)v F

.. ~

C. ?.:: * -}J., J-' A ·7 -.

y I) :.- 5' ......... 'J ~~ lHf;e.-;r _;:.;j; --Iv F c,rJ) k;:t fill l;!:fj~rl) ~ P $ G -'(:>il'~ElEffii-C-':? ~ f.J{ ,3,'. J:: 5 I: tJJ~IjM~ liT Q

Gri nd the contact surfaces of the cylinder h€qcl_, and manifolds so that these can be connected with gradual curved surfaces without any irregularity.

-

-.".;,. ...

. F.VEL SYSTEM

--------------------------------~,'~ .. -------------------------------------------

29'

.", .

8. FUEl SYSTEM-(1) Main modifications.

a. Carburetor.

RSIIised the throttle bore to rneet : the .. specification for high speed driving., ..

±~~:'l!

a. "f-r-j't,..-7

7..0"7 rJt..¥7l1:a:1£31!L, ~J.1~fT(:~Lt::_, f±tJ,l: L ;1;1' 0"

I." ,

, .',
rJi: § f± tt
Item Specification
7..0 ''/ r }vl<:)J.;7"?i 45:f6.
Th rattle valve diameter
=; - :./ /"'( /' f- ;L I) - fl 38,-40;
Large venturi diameter -
A 1:- - It- /"'( /' f- ;L I) - 8011-1
Small venturi
/- l' /' :;.I. ''/ r 160 # -200 #
Main jet size
..:r. 7 OJ'I "; r ~180 # -2.20 #
Air jet size
.:I.:7"V.:;,3 >7-;r:-'f.. ,
I E T7772":2
Emulsion tube 1
71 r" I) /' 7":; I "; l- I 50#
• 1 " ft . , , .
··Idle jet side ... - ..... I , •
;1" :.- 7;;· J.. '/ r 33#: -
I
Pump jet size ,
I .'
, .. - 1" It-/\ iv 7" i
- 170#
Needle valve size I
--- ..
;m flij I 8,Omm
Fuel level height
--_ - ---
.:r.T7.,· :.-;{, I~~ i:3 ! 50mm
Air horn length .!. , :N.-17.

:W£f4;f- /' 7"& '(j 7 { 1('- J

-h J... Y '\" 7 I, &. U;f ,\",.:;( b;.~$'C') '<!i;t (: f-'F', I,

• .~f:'~;",,_~+. ~

~,J1!it~:>"7 t fffflt.£ -t'a" .

b. Fuel pump & filter,

DuEf\:tqr:',the"JeviSion' of the camshaft and carbur,efor, will utilize the eiectric pump.

30

FUEl SYSTEM

No.

! .J.i... }., , £'

' ..

It{ l~ I ~~:~s'~:r:~ '/ i s. T. D
Item
1!/ .i\ I ~ ~ll I ~·1-t'77,L.
Type Electro-magnet I Diaphragm
!
I -
oi .tI:l !i1 I I
I 1500c:c/min . J '!fOO:cc/min ',.
Discharge volume '.
! -,.._........~--
nJ. ,It If I
I O.36kg(cm· ! 0_ 2-0. 3kg/cni
Discharge pressure ,
JE f~ ..". ,'Ef· . I ,
~ 12 V
Rated voltage i
)..,_ 11 ."" ',. ,;
'-"tt tm I 2.3 A ----_
Rated current I I
, ~-18

(2) Required parts.

Part No,

Description

Qty,

21001-SP002

Carburetor set

2 ~ 4

Pump assembly, fuel Filter assembly. fuel

Mouhtfng s,lItl-assy., tuel purpp.~-: _ . "'_':,

2

23100-SP001 23300-SP001 231"09,5Ulnp

" .~

. • ... \ "~l .

, "

"::

(:)

I

Fig,16

Remark

Dellorto DHLA45 x 2 ..

FUEL SYSTEM & ACCELERATOR LINKAGE

31

7 .:l. - IJIt;j(:'- 7'l&ltlF.fl: 'i*WI:it.l,iiil, L. T_t "-oQ :N t-;,_~,,--r']. > j-.-( :i'.1:a-!lZ'i"itJij 1" Q ;:-t:'

. {3) Assembling procedures & assembling standards; Replace with the above parts.

Caution:

Upon instal'lation of the fuel pump, ·:the-' rubber mounting which is supplementary to the as.sembly, must .always be- uti.lized:<· _ .

(3) *llft1J;n~ U*gft~~ M~cg~!l'1~: ::<~

9 7?iz Jk. v-~· ,,1)"/1) o ::£-tri3'J!- .

·Ii- , ...•. - •• :.j. - ~-:---,~ . '" . .! ....... _'. _ .~, '~

-t- '-'r 7' i- -1' d')~!Er:f~\ l,·-W,ffld') 1)':/ '7 ~ t~JE L

-c1;,f);j;To

9. ACCELERATO~H LINKAGE (1) 'Main.mudificatinlls~" .'

Due to the revision of the carburetor, exclusive link~ge has been established.

(2) Required part.

No.

Part No.

Description

Qty.

78022-K E002

Linkage set, accelerator

.. '

, -,.'

.

,

~i' •• ' \ ~: .. -.

, . -

Of': .-

"" ~-

.. " ;.

~ '.~:~:

r

I

: .. ':

l_ ..

"" ~', "

"'-.. ~

'l.,

. ,

... ,

/. ,

~~'.: .

Fig. 17

32

IGNITION SYSTEM COMPONENTS & 'COOLING SYSTEM

-------------_ .... \';,... . ,

10. tGNITION SYSTEM COMPONENTS & COOLING' SYSTEM.

(1) Main modifications.

11).:t1J"~~

a. T fA" I) t: ;:!_ - -'7

;1!;J'I~ ~ 11i' a: ~'iE1U: L, A J q '7)t;.:f" ~ O)iii!t~ 'f{:ft tia: J: ~ ~-i±-( ~ I) ;t J 0

a. Distributor.

The advancing device is revised to statrortarvtype and als0"impr.ovedthe.einr;abili,t¥,·of'tRe'~ spirai.qear.

r][ §

Item

..-------~~-:---'--~-~ ........ ------. .. " "., , - "". ,

I .~, 1> i I J!£. 'L'):\, I ; Centrifugal 'I' I type ,

7.;f, -";; J{-';J i s. T. D
Sports parts
.~ -I 1f
None I Yes
!
M,' 1f,
, None Yes' Advancing j; ~:?EJ'\ i

device' vacuum

" 'type

g ;

5JO-690

Point contacting pressure i

;f 1" / l- 'f" -t ';J 7' Point gap

mm I

I

0.4-0.5

::r/T/-lj-?g:.:I: uF I Condenser.capacity" '1,

1.1

~~19· '

.d" ,. c·

b. AffermitCl!'p'8+i~~:'; " '"

To prevent the over-runninq of the alternator during high speed. revised the pulley diameter;

c. Cootino. system.

Replaced the radiator with a ~a~geq.a:di<ltjol1,,,,

b. :;t )l1 j. ~ '5 7"...:~!)':,

* }[_, 5' ;( ~ 5' 0) ~jJfB~O):t ~ -:\ - '7 / a: pjjl1: T 7.Jt.:.IfJ, 7'_I)_f1'2:-}[~L;j:T?

(2) R,a'luireit.:parts.'· .-..:' 'I '.

.', -: ~.: '. ",-- -

No. Part No. Description Qty.
191 OO-K EOOl Distributor assembly .' l'~", "
2. 27411·KEOOl Pulley, alternator .' c , .• r2d(9")C~ "/.7"

,~·B:TbC 38,-....4tV/400QRPM"

(3) Assembling procedures & assembling standards.

Ignition tirninq

B.T.D.C.- 38 "" 40°/4,000 rpm

HJGINE MOtl"'-ITS, TRMisMISSION HOUSING & SUPPORT

33

l I :;.-:;::.- -::r rJ ::.- T of ::.- ?' .

"7/~ ~ /~3/I\rjV'~?».~;f;f-- t-

I) ~'id:~~

'~:..- ;:;'/ t.,iti!~~IJ' -; ij[}[~ ,: 'lr~T G' !:.:t> , .J:.:';; :..- :7, 7: ~ 7{ :;..: 7~ r '7 /" A ~ 'J :,.. :3 ;".1 \ rj ;; /" '7 (5' )jfffl)' &: Ur7 :..- A ~ "/ :,.. 3 :..- -Ij- ~'- r (4 :i:'! ffi) a: $fr till ::c ;" V):j: To

11. ENGINE MOUNTS, TRANSMISSION HOUSING & SUPPORT.

(1) Main modifications.

Due to the revision of the engine from slantfrig'tb up-ripht type, newly estahlished.vthe ..I:engine':, mounts; 'transmission housing,' (for 5; speed)" and' , transrnlssiorr support (for 4-speedl.

(2) Req:uJrecf parts~

No, Part No.
1 72301·KEOOl
2 12302·K EOO1
'3 31111-KP701
4 57209·KEOOl Description

Qty.

Remark

, Bracket sub-assv., engine mount Front PR H""/ 1

Bracket iub"assy.,"engine mount Front" U1 Housing assembly

Member sub-assy .• engine rear support

T

For 5-speed For 4·speed

(3) Assemilling procedures:: , Rep lace with the above parts.

, .

"

r-

.. ':~

,,',

r-,

_:'.':.

- "

34

S£R-VICE'~STANOAADS

12 m 1i1i ~ ~ ~.

SERVICE. STAN.DARDS

--

Item

~ffli u-i:;-:~ h;--~;;-R':;-::oc:--~-----------___""~-""""""'m'm' 'j

Bottom surface warpage limit

1--- -- ---- ---- ---c·- -------------_+__-

~~OO~~ I

Contact surface angle (fi.) !-

0_10

, I.-- -Jd±tlf: .

. ~ RaCing specification'

i --,---

0_05

---_

45"

J}i EI

S_ T.. D'

45"

IIlm - -- - .. - - ---...,--.--~---- ---.-----

! 1/7-7 Intake.

Valve seat

!fj I) iID rtJ Contact surface width

1.4

.L~~/-;z 1- Exhaust

1.5

1 2+0,,2

- a

:/ I) :..- ~ - -f !:I',:; fJ Cylinder Block

T ~AM~~ I

I Fitting allowance mm I

~~,A ~ -------------+I----------~-----------~

1 Fitting load kg j 2.00Q~3000

~.-~--------~------~~----~~ .. ~~~~--~-.~------~~--~.~.~_j

, "

~ 1) / '9"'

Cylinder: ..

O.Z' ','

I
I
,
j
r
i
I
I
I
.
, , ·(LOS

J:OOUi",ij. ~~IJ:

Top surface warpage limit', mm! 0,05 ! 0.05

~~·}~~~7~·,~J~7~9~r.~~~~~f~I~~.-----------------~~~!~--------~I-------------

V-alve litter holebore-> mm;'[ 20.0QU:--ZO.021· 1

I

p;j:---=-fl~-----------~-"':'I-------~----'--------

Bore mm 75.00-75.05 79.03'-:-79.08

r--~~.~~~~--~---~~-+I----_~----~-~---------_J

, I\-Ht:l: jJ~ If. ,·.'1

i Wear limit rnm I' .'

'-~~T~~/~{-,~~~~~.~~~--~----+i~'~----~--~~~-------------~-

I Taper, roundness limit mm: 0_,02';

t-~~ IJ / ?,pq1f~ !

i Cyl inder bore d iiference mm I

0:05'

"7 1 1- Liner

0.055-0.15

I::"A ~ / rHi .' mm f ~ _", '! , , ' .. ·1:
Piston diameter '.7'1. 9F ... 75 .02' I . T8 ';% -78:, 9:8
----- __ L __ ~_ ,
;_" I) / 9- c (l) T 'M I ~- -- -
Clearance between cyl inder mm i 0.03-0.05 i 0.07-0.10
t:<7- "/ t:" / . ~" tj: . .$~m' I !
Piston pin fitting temperature C· 70-80 .' . BO'
I' ..
I
t:";Z " / IJ /7" I :J ;,- 71.--·/ ~ 3 / I) /7- No.1 I -
{5- '. ) 0 l' ~ rl3~ Compression ring No.2 mm I 0_15-0.35
,
Piston ring gap i----- .~--._.._----j - ..
;t1 }~ I) ;,; 7- Oil ring rom 0.20-0,90 j
. - ..
:J;,-7'v';t~3 / I) / f . _--
1:::.7- r :,,- IJ :< f tili Compression ring mm 0_03-0.07 0_03-0.05
. c.,(l) l' ~ ra' -. '. .._
Clearnace between .;t -1 )L.- I) /f mm I
'ring & groove' OU ring 0_015-0,06

tVA " :,. e""./ ;~rI , . m~ f;· I
'"Piston oln outer d iarrreter 17.999:"'" IS ,0-11, 20.005-20.017
-
_,.- ... .' . " ..

__________ ~~,~~-------------S-E-R-v-rC-E-s~T~A~N~O~A~R~OS~-------------- ~35

- "
- . "
III El v-7,f±f~
Item S. T. D
- -·-'r ." Racing specification
11!I,t),~lll& (lOOmm I:"? ~ ) .....; ..
Sand limit (per 100 mml rnm 0.05 0.05, 0
:Q L h~Jl!f.l (lOOmmi~"? ~)
Twist limit (per 100 rnml " ' mill 0.15 :0.'05
,."
f ~Jl! Ii " , "
*i~g(I -
,A '7A ~ -t ~ FJJ l.irnrt mm 0.3 0.3
.~ ~ fa ' .,
Large.end thnrstclearance ", ,
Speclffed ' . mt1l' o.ue ...... O.214 -
.•.. " ._ .....
pH Ii' :.'fj:
e>tu: \::'/0)1" H~1 Limit mm 0.05 0.05
Clearance between I ~ ~ f~
Specified mm 0.004 -0,008 0.009-0.014
" pH oc
r.:.y Ij >',7' iruT s F .. ' Limit mm 0.10
Bearing oil clearance ~ '~ fill
pin & bore Specified mm o ' 024 - 0 , 048 0.04-0.06 I) '7 :;, I)' ~ 1" '7 ,.. Crankshaft

10m

0.02

0.03

0.3

I :":

I1!I I} ~1llJi' Bend limit

,,-

0,3

(}_'."04- 0, 222 '_', _.1

or , / { " t: fIj f!£ I '- " , r'l T

Taper, roundnessllmit mm ,,' -,i:'f)'iO~r:'LI-~ I'. "

_______ ~ ~~ ~ __ ~_,'~-'~·,;;'~;,~~~s~t~ha~n~,~----~~--~~-J

%'-\-:_"',_T)~ iHl ,,:~ '<~'."

Journal ctiameter mrn.J ' 49£9'1'6":"'o{l,Pf3?::-.,':', , ----,'.::;:,:

;:t. 7A I- -t ~ ra~ Thrust clearance

,1 ,KH' I!f. -_

I' Limit

r ~ ~ (Ii I . Specified"

mm

mm

:/ t' T)t.-;It l' :. ra~ I

Journal oil clearance mm 1

.,J1

0,016 !:'O, 040

0.05-0.07

-'

:; -( ~ :;, ~f 7- z -:..-, A 7'tl T·;; I- Timing Chain Sprocket

•
l:.hb~JV! (~;/]10kg) mm !
Deflection limit (l01d 10 kg) 13,5
~\.{7'[...-:/3/ '_
r > j{ Im~~HIt i ,--,~-_-
Vibration damper thickness limit mm ; 7 I
,:.:;;. ,.'''' J

7/':/3/, 7'7 .> ~/ -t - T,A 1r~ D:l ffl[ ~H It mm I --
Tensiorr plun-gerhead thickness limit
7J t: -'i ..\;' 7 " : 7'1 ~ ,/ -7'-:;::" 7rr~ ,; H7)I1t*H~& -,
113.8
Camshaft timing sprocket wear limit mm i (rv~easu re d iamT~r _
)7/7:;4;'7r-, w/chain install
7' l' ~ :,....)' A 70T '/ ~ 0)~lH1Vi mm I ( . )
Crankshaft timing sprocket wear limit 59,4
( -
I " ),
r
f-,:I. ,'/' f$rHHoc mrn 1 (5&1J5 kg) 1 -'--
, Chain-deflection I im it 272..7
UGad,5 kg) ,--
,,-' J'_6 '.:...SE_R.:...:V....:.:I~~)iTANDARDS

l'lL-"f Valves'

mm

38

JJi' §

Item

I

, 1-

S'; ,T;- D'"

I i- -'---A1ttR

, ',Racing specification

Head diameters>. c',

,~ -If:

Overall lengths

mm i 29 '-33,'

~--T~~~:::----'-~--m-mt':____,,c__.10~0-.1~~-.'7"·" t--' -~'-~,,~----:- " __ " 96.8 -

ATJ" JH,f Stem diameters

mm

45
7.965-7.975 ) • 6.571-6.587
l ':"
7 _ 960~7. 975 I 6.571~6_587
--- , ,
0.035-0.065 0.05
---
0.035-0.070 0_05 ,

rnrn 1

J mm i .

-Ii -1 1'---7' -/ ~, ::I-

e O);ftT~ Fa) Intake

Oil ctssrance ,. "," ,_ ,':--.L~::f;-': :-/;:,=-Jl..:;;-;f-:-"---~:_c:_~~-.:;_~-------.-+-------

» , betwe~f1 ~tJide'pasg'i~~;:::, '~Exhaust, mm i

ji-1I-"-7")~;L -{/7 '7 I I

~.O)iIRT ~ F,,'JilVl: ' Intake l>, mm I ' 0.08 I

GWcleara~ce'l-jmif 0" ;! -----:,.L::;:-,-;::f:::,::::"/{~, ~'-:;:h;-:"'-;::-P-;--' -:----::------f-, =:': .: ;.;.., --:----~I-~~---:----;,--~

between guide bushing 'I Exhaust mm I 6.10 'I

I ~

0.08

o.os

J { II.-- 7' r... -J F'

mJ~~~1§t

"

1<" J'" Of ~ - to Va Ive Seats

'1if)iID1':I~ Contact ang I,e

(Jj) I

45'

;l:~: 4i' !? = I~

,,' 1-', _ContactwidJ'h,

4i r) lID ji$ iE jij tit

Contact surface correction angle

1/T '7 I

" Intake mm I 1.4 I.2~~~

- !-j --:-, -, .L::-:;;.t-::--~'J::-'~-=A-:- .. -;-,,-,~_-, ------------jl'~--~----=---__J!~· ~~,,---~~,,.:-,.-

! Exhaust ~ '--_mm~,-ti __ . __ 1_, 5_"-_" _' '--~",_·~·+_l ~~_" L_.~2~·:=-e~' o~·2_'.-_,_,,",..,~" '_',~;

(.!]t) I 30',45',65' I

J '\ J(... -J' jj -( " 7'·/::.-.::l Valve g!Jide bushing

fl.] fl I
Bore rom I 8.01-8.03 6.60-6.62
j~ jY.- rom I
,x I
Outer diameter 13 . 035~ 13.045 13.04-13.05
-1 /7- '7 mm I
. «'J' r- J:im 0) ;:c ili·,l. jt" . .Intake 18 n.s
Protnrsiorrvoturneerrtcr" _L;;f v> A " .. mml I
-.. head Exhaust : 18 U.S
,
:fJ"SJ6h-~1Jt c'l
Fining temperature 100-130 130
- " " " " SERVICE STA-NDARDS

37

7 ., -{ * 1" - Jf, Frywheel.

~ § L-- -.7. f±t~
Item S. T. D
m.h ~JM£ Racing specification
-
Run-out lirnit : mm 0.2 0:10
" 1J .L. ::... '\' 7 f-. Camshaft

ElBI'J ~lH'i ~ ".
Bend r " ' -
limit 0.03 ~ .... -
~~ &. ,

:A-'7;J.. I- T~M Limit mm 0.3 I
Thrust clearance ,
~ ~ (~ :.
Scscified ". . O. 070-"::'0; 138
mm ."'"
,
~~ f5t. -.
.. -,
iff] T ~ n" Limit mm O. I '
-.",_~- r r
Oil clearance t~ !$ (111 ..,--. . -_.-------
Specified - mm I 0.025 -0. 066 I

r
. _
No. 1. mm 43.209 -:0 4.3 .2.25 I
I
I ..
,. l
"
Y't -7 Jt.- lHl 0.2 mm 42.954-42.970
---.'
Journal diameters
No.3 mm 42.704 -42.720

..
No.4 mm 42.459-42.475 '1'
.. .fi
., /7 7 ..
f; L. jib' ~ ~R J.'i Intake c. ·mm:.· 36. .. X7 ..
Cam height limit I .J:~j-7.·r
I I ..
Exhaust mm , 36.07 !
f--'--_._. ;
l' :/"7: -: '7 ." " "7 '," -.-----
I .. . ..
'. nL~~ ~~f@: Intake. ., mm 36. ·t69'~36 .. 5&9 .. 3L82 ,
r I --
'. Cam hsight-specified . [ .J: =t- './ ~.7. r , -
·1 :
.. 36. 3'69 -3~. 469 I
mm I' 34:.82. .,
. . . ". ,\ : . • Exhaust
- "':"'.-."-.-----:---.-~' ---.- ,...,.., - C •• J ,. ,'I' ~
I ., /7-7' R __ '_~..::-~-_; ....... ~-_.L:...........:.. ..
-~ f '. ...
nt. I) 7 r Intake mm I 5'.72 7:3
i I
Cam lift I ..:r.-tj-7. l-
I [ I
I Exhaust mm i 6.02 7,3
;!-t -T Jt.- f~F9 , j--/e-Ffi. .. _ -
I i .-
Taper, roundness I imit at journals' .. ·d. , mm 0.02 --.
, /
_c .. I "\
"V. ~ / \)1.- -; I) 7 ~ Valve lifter

j~ ..
{L . '. '.' '. ,., ,
- "
Diameter; mm I 19.978-19.999 I
.~~ ..
~~
/,0'"J 7T'r;: c(T) & mm I I
T ~ 1~9 limit 0.1
Clearance between ~ ~ fli mm I ,. --
block bore." Specified 0.015 - 0.029 i <--
. ,.~. t.".~.
. , ..j;
..