20. SERVICE DATA AND MAINTENANCE SCHEDULES 20-1. Tightening Torque .......000c0ceeeeeereeesreertetsenet tees sees 8 <2, Service Data wyoss-e++-e0siiess (ss sewnnes+esesisaee esa stinging cso 251 20-3, Periodical Inspection Schedule ........2.60:ss00¢:0reeneeeeees 257 2 -20-1. Tightening Torque In threaded fastening parts holding down a component in place, the holding force is preserv- ed primarily in the male and female threads in contact, Screw threads are capable of with- standing this force up to a certain limit. Here occurs the need to tighten them without exceed. ing the limit, and this need can be met by using torque wrenches, Fastening parts, for which the limit is specified because their fastening or holding function is critical, is listed below. Use torque wrenches and adhere to the torque specifications when Fig. 20-1 tightening them at the time of periodical inspec. tion or overhauling or servicing, Tightening torque System Fastening parts uw len a Cylinder head bolt 55~60 | 55~60 | 40.0~430 Spark plug 20~30 | 20~30 | 145~216 Inlet & exhaust manifold nut 18~ 23 | 1.8~23 | 130~ 165 Camshaft timing pully bolt 50~60 | 5.0~60 | 36.5~ 43.0 Valve adjusting nut 15~ 20 | 1.5~20 | 11.0~145 Timing belt cover bolt 3~4 [o3~04 25 Crankshaft pully bolt 50~ 60 | 5.0~60 | 365~43.0 Connecting rod bearing cap nut 28~32 | 28~32 | 205~ 230 Crankshaft bearing cap bolt 43~48 | 43~48 | 31.5~345 | Flywheel bolt 40~45 | 40~45 | 29.0~325 Engine Oil pressure unit 12~15 | 1.2~1.5 | 90~105 Oil filter Assiy WO~15 | 1.0~15 | 75~106 | Oil filter stand 20~25 | 20~25 | 145~180 Engine rear mounting nut and bracket bolt ti~ia [1.1=14 | 80~100 Relief valve spring retainer 15~ 20 | 1.5~20 | 11.0~ 14.6 Oil pan bolt 4~5 |04~05 | 30~35 Oil drain plug 20~ 25 | 20~25 | 145~ 180 Engine mount bracket bolt (cylinder and body) | 30~ 40 | 30~40 | 22.0285 Engine rear and front mounting nut 23~ 28 | 23~28 | 165~ 200 Cylinder head cover bolt 4~s [o4~05 | 30~35 —mg_‘System Fastening parts Tiavenneea N.m kgm Ib-ft Gearshift arm nut e~i4 | 09~14 | 7.0~ 100 Gearshitting | Searselect arm nut o~14 | 09~1.4 | 7.0~ 100 control ‘Transmission case bolt 15~20 | 1.5~2.0 | 11.0~ 14.5 Oil drain plug and level plug (Hexagon type) mar | Meee | hese? Extension case bolt 15~20 | 1.5~20 | 11.0~ 14.5 -transmission| Rear mounting bolt 15~20 | 1.5~20 | 11.0~ 145 Gearshift lever case bolt (8 mm) a~i2 | 09~12 | 7.0~85 Gearshift lever case bolt (6 mm) @~10 | 06~1.0 | 43~7.0 ‘Stopper plate for shifter fork shaft 15~ 20 1.5~20 | 11.0~ 14.5 Cross joint flange yoke bolt 15~25 | 1.5~25 | 11.0~ 180 Side bearing cap nut 20~25 | 2.0~2.5 | 14.5~ 18.0 Ditterential Drive bevel gear bolt 65~80 | 6.5~8.0 | 47.0~57.5 Drive bevel pinion nut 110 ~ 170 |11.0 ~ 17.0 | 80.0 ~ 123.0 Differential carrier nut 15~ 23 1a" 23 11.0 ~ 16.5 Oil drain plug 40~70 | 4.0~7.0 | 29.0~ 50.5 Shackle pin nut 30~55 | 3.0~5.5 | 22.0~ 39.5 Reef spring nut 45~70 | 45~7.0 | 32.5~ 50.5 Reef spring U bolt nut 30~45 | 3.0~45 | 22.0~ 325 Steering knuckle nut 80 ~ 120 | 8.0~ 12.0 | 58.0~ 86.5 Front strut lock nut 70~90 | 7.0~9.0 | 51.0~ 650 Front strut support nut 10~ 18 1.0~ 1.8 7.5 ~ 13.0 ‘Suspension - Ball joint stud castle nut 40~70 | 4.0~7.0 | 29.0~ 50.5 Wheel nut 60~ 80 6.0~8.0 | 43.5~ 57.5 Front suspension arm shaft nut 40~ 60 | 4.0~6.0 | 29.0~ 43.0 Tension rod nut 40~60 | 4.0~6.0 | 29.0~ 43.0 Tension rod castle nut @0~ 100 | 6.0~ 10.0 | 43.5~ 720 Tension rod bracket bolt 30~55 | 3.0~55 | 22.0~ 39.5 249 —System Fastening parts sation tore Nam kom ibft Steering shaft nut 25~40 [25~40 | 180~285 Steering rubber joint nut 16~25 [15~25 | 11.0180 Steering rubber joint fainge bolt 20~30 [20~30 | 145~215 Steering gear box bolt & nut 70~ 90 |7.0~90 | 51.0~ 65.0 i ee Seca tenia GE 40~55 | 40~85 | 290~305 Steering Center lever nut 80~150 |8.0~ 180 | 580~ 108.0 Tie rod end lock nut 80~75 |50~78 | 365~ 540 Tie rod end ball stud nut & Drag ling nut 40~70 |40~70 | 290~605 Brake backing plate bolt and nut | 18~28 [1.8~28 | 130~200 Brake master cylinder nut 25~40 |25~40 | 1a5~2a5 Brake tube union nut 18~18 |1.5~18 | 110~130 Brake [Brake flexible hose nut 20~40 | 20~40 | 145~285 Brake shoe adjusting nut 6~9 [06~09] 45~65 Brake pipe Sway joint bolt 4~7_|04~07 | 30~60 Brake pedal bolt nut 18~28 [18~28 | 195~200 For other bolts and nuts not listed above, refer to this chart: Tightening Torque Conventional or “4” Marked Bolt “7"" Marked Bolt Fe benetee (el am kgm lb-ft Nm kgm lb-ft 5 2~4 | 02~04 | 15~29 | 3~6 | 03~06 | 22~44 6 4~7 | o4~07 | 30~50 | @~12 | o8~12 | 60-88 a 10~ 16 | .0~16 | 70~115 | t@~28 | 18~28 |130~200 L 10 22~ 35 | 22~35 | 160~250 | 40~60 | 40~60 |200~495 cea) um Conventional Bolt "7" Marked Bolt cer=68) "4" Marked Bott —250—20-2. Service Data ENGINE item Standard Service Limit 11.8 kg/em® (163.5 psi) 300 r/min 9,0 kg/m? (128.0 psi) 300 r/min] Compression ; pressure Difference between 1.0 kg/em? (14.2 psi) 300 r/min cylinders ‘Vaive clearance | Cold (0130.18 mm (0.005 ~ 0.007 in) (Unter, Exhaust) V ioe 0.23~0.28mm (0.009~ 0.011 in.) seein hintaemeerere Ignition Timing 14° B.T.D.C. at 900 r/min (rpm) Flatness of gasketed surface 0.05 mm {0.002 in.) -g | Flatoes of manifold net (0.1 mm (0.004 in.) = | et (Outlet ‘Ot mm (0,004 in.) i a ae & | vane seat| width [exhaust (13~1.Smm (0.0512 ~0.0800in) Seating anale ae ‘amshaft/Journl clearance 19.050 ~ 0.004 mm (0.0020 ~ 0.0036 in.) | 0.15 mm (0.0059 in. Camshaft thrust clearance 10.050 ~ 0.150 mm (0.0019 ~0,0059 in) | 030mm _(0.0118in.) inlet 36.152mm (1.4233 in.) [36100 mm (1.4212 in) Caleta Exot (S6NBZmm (1.4233 in 36.100 mn (1.4212 in.) {Base circle + li) 7 “ i 7 Fuel pump cam|33.300 mm (1.3110 in) [33.000 mm (1.2992 in) Camshaft deflection ———_———— 0.10 mm _ (0.0039 in) niet 6.968 ~ 6.980 mm (0.2742 ~ 0.2748 in.) | Valve stem diameter 2 Exhaust [6.956 ~ 6.970 mm (0.2738 ~ 0.2744 in.) & Intet_ 7,000 ~ 7.015 mm (0.2755 ~ 0.2761 in.) Vaive guide 1.0. — : [Exoust | 7.000~ 7.018 mm (0.2785 ~ 0.2761 in.) FT ave guide ovale inet (0.020 ~ 0.050 mm (0.0008~0,0019in) | 0.07 mm (0.0027 in. § | stemelearance [Exhaust 10.030 ~ 0.060 mm (0.0012 ~ 0.0023 in.) | 0.09 mm (0.0035 in.) 5 [ css rsa. [tt 807 120mm (0.0315~0.0472in) | 0.6 mm (0.0296 in.) 2 head periphery: [Exhaust 0.80~1.20mm (0.0315 ~ 0.0472 in.) 0.7mm — (0.0275 in.) Contact width of [inlet 7.3~ 15min (0.0512 ~ 0.0590 in.) — valve and valve seat | Exhaust 1.3~ 1.5mm {0.0512 ~ 0.0590 in.) Saou gael 41.7 mm (1.8779 in) 46.5mm (1.8307 in.) free length Exhoust (47.7 mm (1.8779 in) 46,5 mm _ (1.8307 in) ae 26~ 30 kg (67.3~ 88.1 1b) for 24 kg (62.9 1b) for fitting Valve spring iting length 40 mm (1.57 in.) Tength 40 mm (1.57 in.) protoad Ganson (20790 (67.9~ 66.11) for 24 ka (62.91) fr iting Fiting length 40 mmm (1.57 i.) length 40 mm (1.57 in =251—tem Standard Service Limit Recreate. f4.965~ ias60mm (0580 ~ asso) E [Roser arm 0. h.965~ 15005 mm (0590 086 in) Es lescnane = 005 ~ 0.010 mm 0.0002~ 00018in) | o@7 mm WoooR7 mI & 8 clearance exhaust P.008 ~ 0.040 mm (0,0002~ 0.0016 in.) | 0.07 mm (0.0027 in) learnt cee 0108 mm {0.0023 in) Flatness of gasketed surface ce 0.05 mm (0.0020 in.) a | Oviner bore 7.01 2005 ~ 62.020mm fasts ~a4ar7 ml =z Difference in bore between cylinders oe pe ~ | 0.05 mm (0.0020 in) & [Weer limit on bore ee == 0.05 mm —(0,0020 in.) Cylinder-to-piston cleerance }0.040 ~ 0.050 mm (0.0016 ~ 0.0020 in.) [Standard [61.960 ~ 61.975 mm (2.4393 ~ 2.4999 in) J] piston clara fee ra e2400-~ 2.475 am 1.2560 ~ 2.4588 in Eee eer 5 low fe Tepriog _[1.52~ 184mm (0.0588 ~ 0.0608 m) ———— & |iam "°°" [andving —.61~ 1.59 mm (00604 ~ 00007) lot ring :2.81~ 2.83 mm (0.1106 ~ 0.1114 in) ——— Piston pin diameter 18.995 ~ 16.000 mm (0.6297 ~ 0.6299 in. ton pin clerancn in eon. rod__ 0,008 ~ 0.016 mm (0.0001 ~ 0.0006 in) } o:05 am (0.0020 in.) HTopring _(1.47~1.49 mm (0.0578 ~ 0.0586 in.) Piston ring thickness? nd ring [1.47 ~ 1.49 mm _ (0.0578 ~ 0.0886 in) | (Oi ring 45 mm (0.0177 in) —— Ringslearancein [Topring __[0.03~0.07 mm _(0.0012~0.0027 in) | O12mm (0087 ma | 2 soove [raring |0c2~ 0.06 mm (0.0008~0.0025in) | 0.10 mm towoag ny 5 epring __[0.18~0.35 mm _(0.0059~0.0137in) | 07mm (00275in) E Pston rng end gp [ancring 0.18035 me (0.0059 ~ 0.0137 in.) _[ 0.7 mm (0.0275 in.) [Oi ring .30~ 090mm _(0.0118~ 0.0354 in} | 1.8mm (0.0708 in.) Piston ring free |Top ring 5 mm. (0.2568 in.) —————_ end gap landring [85mm (0.3348 in) | ———— Crankshaft deflection (middle) ———— ©.06:mm (0.0028 in.) [Crank pin diameter [37.985 ~ 38.000 mm (1.4954 ~ 1.4960 in) [crank pin clearance incon. rod 020 ~ 0.040 mm (0,0008~ 0.0016 in.) | 0.08mm (0.0031 1 | Comesing rod small endtore “16.000 16011 om (0.6300 ~ 0.6308 in) © Jerank journal diameter [49.985 ~ 60.000 mm (1.9679 ~ 1.9686 in.) Bearing-to-journal clearance [9.020 ~ 0.040 mm (0.0008 ~ 0.0016 in.) | 0.08mm (0.0031 in = 252—Item Standerd Service Limit ‘Crankshaft thrust play 9.130 0280 mm (0.0061 ~0.0110in) | 0.3mm _(0.0138/n) cere! end thrust |g.49~0.20mm (0.0039~0.0078in.) | 030mm (0.0118in) | clearance E Twist —— (0.10 mm _ (0.0039 in. 5 | connecting rod Straightness —————— (0,05 mm _(0,0020 in.) CLUTCH & TRANSMISSION Item Standard Service Limit Pedi play 20~ 30mm (0.9~1.21n.) ——— +g | Facing wear (Redhead depression 12. (0.051) 05mm _ (0.02in) 3 [Facinginput shat aeration backlash] | OS mmm (0.02) ‘iutch release arm play 3~4 mm (012~0.16 in) —— cman aan od age enna RSS SS | SEE (0.02 in.) Key slot width of synchronizer ring [9.6 mm (0:38 in) 2.9mm (0.39in.) Fork shaft ___|fsceing [Free length of No.1 |18mm (0.767 in.) 17.0mm _(0,669:n.) g | spring 2 i 5 ate fading Yoke In eRHON [p69 ~ 0G mm (0.0008~0,0024 in) | 1mm (0.0039) case bush | Low & second gear backlash 0.4 mm (0.0039 in.) 03mm (0.0118in) Third & top gear backlash [0.1 mm (0.0039 in.) 08mm — (0.0118in.) Reverse gear-roverse idle gear ; pis 0.1 mm (0.0038 in.) 03mm (oorrsin) | LUBRICATION [ Item Standard Service Limit ‘uner gar periphery eearanee—Jo.1g~ 020mm (.0047~00078in) | O3 mm (0,0118in.) in pump case ‘Outer gear tooth clearance in a is peas l0.25~0.40 mm (0.0098 ~ 0.0157 in.) § [nner oar oot cleaner Joen~o.g0mm (0.0296~ 0.0316in) |_| | pump cose 3 ‘Oil pump side clearance (flatness) _|0.046 ~ 0.120 mmm (0.0018 ~ (0.0047 in.) | 0.17 mm (0.0067 in.) Free length {60 mm (2.36 in.) ——— tele vive | 039 im) ring ron k \ so Ti erie Pa (3.280 6) 1.200 ka (2.645 1b) Fer prenure of oll pressure switch [0.2~0.4 Kalen? (2.64~ 6.68 P5) —— -253—COOLING system tem Standard Service Limit Fan belt tension as deflection under 10a (22 Ib) push applied to middle] 10~ 15mm (0.4~ 06 in) eee Point between pulleys Thermostat startto-open Fone 5 on 82°C (179"F) “86°C (190°F) —__ ‘Thermostat fullopen temperature | 96°C (208"F) “100°C wizPF) ——_ Valve tft 8mm (03tin) a “For Finnish market DIFFERENTIAL [- tem Stendard Service Limit Side gear backlash 9.05~ 0.18 mm (0.002~0,006 in) | _ ————— Bevel gear backlash 0.08~ 0.12 mm (0,003~ 0,005 in) | SUSPENSION Item Standard Service Limit Strut stroke Front_| 121 mm (476 in ‘Shock absorbers stroke | Rear | 160 mm (630m) Rear lea soring a ; fe Amount of bow| 113 mm (6.48 in) —___ Front coll spring free length 288 min (10.85 in 255 mm [10.04 in) Rear reat spring free length (Center distance between shackle) | 100mm (39.37 in) -254~STEERING SYSTEM iter Standerd Service Limit Gear ratio (Gear box) 15.4 (0~4°) ~ 17.4 (over 26.5°) ‘Steering angle, inside 3 ee ‘Steering angle, outside 2 Sanaannannand ‘Steering wheel diameter 384mm — (15.11 in.) —-— Minimum tuning ris aim (13.454) — Starting toraue of worm shaft 2.0 ~ 6.0 ky-em (0.145 ~ 0.362 lb-ft) —— Tire inflating pressure Front 180 kPa (1.8 kg/cm”, 26 psi) OT {not loaded) (4,50-12-8PR Tires) Rear 180 kPa (1.8 kg/em?, 26 psi) eae Tire inflating pressure Front 240 kPa (2.4 kg/m”, 34 psi) er (280-12-9PR Ties) Rear | 375 kPa (3.75 ka/om?, 63 pal —— feet in pressure Front 160 kPa (1.6 kg/cm?, 23 psi) Peer (145R 12-6PR Tires) Rear 160 kPa (1.6 kg/cm?, 23 psi) eee Fes infin pressure Front 180 kPa (1.8 kg/cm? , 26 psi) Peer (145R12-6PR Tires) Rear 280 kPa (2.8 kg/om®, 40 psi) eecEnESeia: Vehicle with 450-1280R | 11~ 15mm (0.433 ~ 0.690 in) —— esgid Vehicle with 145212-6PR: 3~6 mm (0.118 ~ 0.236 in.) PEE Eee ‘Camber 1° 30" ral Timm (043in) Kingpin inclination 12° 30" Caster 2 30" er BRAKE tem Standard Service Limit Brake drum inside diameter (220 mm (8.66 in.) 222mm _ (8.74 in.) Brake drum “out-of-round” Omm (in) 05mm _ (0.02in.) poccrrinrononet Timm (027in) 3mm (0.12) Pedal travel 15~ 20mm (059~0.78 in) eee -255—ELECTRICAL Item Standard Servis Limit Tgrition timing 14° B:T.D.C. at 900 rimin (rom) Ignition order 1=3-4-2 © [ermemiiae oF =n concen trainee aie oa & | pnition cot, Primary winding ‘About 3 ohm {inclusive of the 1.6-0hm resiatance restr) Sree Tgntion cal Secondary winding | aout @ kloohme resivtance Voltage 12 volte —— | Output 06 kw eee 3 [7 ating 30 seconds — & | _Beashleeth 19mm ___(0.75in) 12mm (047 in) § [Number of prion oth 9 commutator diameter 325mm (1.28in) 30.5 mm (1.20) Mica undercut 05~0.8mm (0.02~008in) |a.2mm (0.007 in) ‘Nominal operating voltage 12 Volts Maximum alternator output 35A Effective pulley diameter 65mm (2.56im) —— _ |__Meximum permissibe alternator speed) 13,000 cimin bpm) a g Working temperature range —40~ 80°C (-104 ~ 176°F) — & [Rotor Ringtering scar eanance | 95 ohms ‘© | Brush lenath 165mm (068in) 110mm (045 in.) & Standard output voltage and current | 13.8~ 14.8 Volts, 20A minimum —————- Regulated Voltage 13.8~ 14.8 Volts ——— Voltage-elay cut in Voltage 4~58 Vat — Prescribed eut in Voltage 4~45 Vols ———— Field circuit resistance 6 ~9 ohms a - 256 ~20-3. Periodical Inspection Schedule ‘A machine is in the best operable condition at all times where it is systematically inspected, re-adjusted, vn Tbricated and serviced at regular intervals. Such a machine is safe to use and works 10, the best of its ‘bility. The following schedule has been carefully formulated for the ST90, ST9OK and ST9OV, with a view to attaining what the above concept implies: Interval: : km (x 1,000) 7] 10 | 20 | 30 | 40 | 50 | 60 | 70 | 80 Co caine udgen miles 1,000) 1] 6 [12 | 18 | 24 | 30 [36 | 42 | 48 whichever comes first. months 1| 6 | 12 | 18 | 24 | 30 | 36 42 | 48 ENGINE 1. Water pump (Tan) drive belt (tension, wear,ete.) | A|~- [1 |-|R]- it) IR 2. Camshaft timing belt (damage, wear) ee i) 3. Valve clearance A|-|A|-JA|-|A]- A Engine bolts Al evinder od and maitld fig | T | - |T [- |T]-|T|— | 7 5. Engine oil filter rRiR|RIRIRI|RIR[R R 6. Engine oil API Grade SD or SE R Replace every 10,000 km (6,000 mi les) ‘API Grade SC R Replace every 5,000 km (3,000 miles) 7. Engine coolant -{-|-|-|R -|-|R B. Cooling system hoses and connections "eakege a.) | — | — | 1 |= |b Lo ri- ft 9. Exhaust pipes and mountings{leakage, damage) -l-Jif-jJey-jeqet! IGNITION 10. Ignition wiring (damage, deterioration) Bef epee ee eee 11. Distributor cap and rotor (wear, deterioration, etc.) -|- ft bji- fiji 12. Spark plugs and distributor breaker point -|R/R A \Ri|R IRR 13. Ignition timing tlAlA;AJAIAIA AIA 14. Distributor advance -|-|jt fo Eb “A” + Check and/or adjust if necessary ““T””:_ Tighten to the specified torque, “RY > Replace or Change “1”: Lubricate “C” : Clean “4° + Inspect and correct or replace if necessary =257-Interval: km (x 1,000) 20 | 30 | 40 [50 [60 | 70 This interval should be judged [rites (x 1,000) 12 | 18 | 24 36 [42 | 48 by odometer reading or months, whichever comes first. months 12 | 18 | 24 | 30 | 36 | 42 | 4g FUEL Paved-road Clean every 10,000 km (6,000 miles) 15. Air cleaner Dusty condition Clean every 2,500 km (1,500 miles) or as required Replace every 40,000 km (24,000 miles} More frequent repiacament if under dusty driving conditions. 16. Cyclone Clean every month 17. Accelerator cable & Carburetor shafts PRL) 18L TBE] HL) LL] PL | LL 18. Fuel tank cap, gas lines and connections ‘leakage, Hj-t-}-fry-f- damage) 19. Fuel filter 20. Idle speed and idle mixture CRANKCASE EMISSION CONTROL 21. Crankcase ventilation hoses and connections FUEL EVAPORATIVE EMISSION CONTROL 22. Fuel vapor storage system, hoses and connections ELECTRICAL 23. Wiring harness connections and headlights CHASSIS AND BODY 24. Clutch pedal (play) 25. Brake fluid (level, leakage] 26. Brake pedal (travel) 27. Brake lever and cable (play, damage] 28. Brake drums and shoes (wear) 29. Brake hoses and pipes (leakage, damage) 30. Tires (Abnormal wear and pressure, etc.) 31. Wheels and hub nuts (damage, tightness) 32. Shock absorbers (oil leakage, damage) 33. Propeller shaft (tightness, damage) 34. Transmission and differential oil (level, leakage) ~ 258Interval: km (x 1,000) 7] 10 | 20 | 30 | 40 | 50 60 | 70 | 80 This interval should be judged | miles (x 1,000) T] 6| 12) 18 | 24 | 30| 36 | 42 [48 by odometer reading or months, whichever comes first. ‘months 7 | 6| 12] 18 | 24 | 30] 36 | 42 | 48 35, Bolts and nuts (tightness) tl-|t]-|tf-|tj- | 36. Steering condition (play, tightness, leakage, etc.) | | |! | | Test drive on completion of each service 37. Test drive “4A” + Check andlor adjust if necessary “T”: Tighten to the specified torque “Rp”: Replace or Change “1: Lubricate "C": Clean “47s Inspect and correct or replace if necessary NOTE: The item 16 is applicable to vehicles mounted cyclone. peor ee eee Secret = 259—260—