2011r Service data.pdf

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Model: RM-Z250L1 E-03, 19, 28
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
IN. & EX.
IN. & EX.
IN. & EX.
IN.
EX.
Valve spring tension
IN.
EX.
STANDARD
31
(1.22)
25
(0.98)
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)
—
4.500 – 4.512
(0.1772 – 0.1176)
4.475 – 4.490
(0.1762 – 0.1768)
4.455 – 4.470
(0.1754 – 0.1760)
—
0.9 – 1.1
(0.035 – 0.043)
—
—
—
Date: June 18, 2010
Unit: mm (in)
LIMIT
—
—
—
—
—
—
0.25
(0.010)
—
—
—
0.05
(0.002)
—
0.03
(0.001)
37.1
(1.46)
37.5
(1.48)
—
142 – 157 N
(14.5 – 16.0 kgf, 31.9 – 35.3 lbs)
at length 33.55 mm (1.321 in)
137 – 157 N
(14.0 – 16.0 kgf, 30.8 – 35.3 lbs)
at length 33.55 mm (1.321 in)
1/12
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
34.78 – 34.83
(1.369 – 1.371)
33.98 – 34.03
(1.336 – 1.340)
0.023 – 0.066
(0.0013 – 0.0026)
22.003 – 22.025
(0.8663 – 0.8671)
21.959 – 21.980
(0.8645 – 0.8654)
—
13th pin
—
Unit: mm (in)
LIMIT
34.48
(1.357)
33.68
(1.324)
0.150
(0.0059)
—
—
0.10
(0.004)
—
0.05
(0.002)
Unit: mm (in)
LIMIT
—
0.120
(0.0047)
Nicks or
scratches
76.880
(3.0268)
0.05
(0.002)
5.7
(0.22)
0.50
(0.020)
0.180
(0.0071)
—
—
—
16.030
(0.6311)
15.980
(0.6291)
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
Oil
Piston ring thickness
Piston pin bore
Piston pin O.D.
1st
IR
STANDARD
400 – 800 kPa
(4.0 – 8.0 kgf/cm
2
, 57 – 114 psi)
0.030 – 0.040
(0.0012 – 0.0016)
77.000 – 77.015
(3.0315 – 3.0321)
76.965 – 76.980
(3.0301 – 3.0307)
Measure at 8.0 mm (0.31 in) from the skirt end.
—
Approx. 7.1 (0.28)
0.15 – 0.25
(0.006 – 0.010)
—
1.01 – 1.03
(0.0398 – 0.0406)
1.51 – 1.53
(0.0594 – 0.0602)
0.97 – 0.99
(0.0382 – 0.0390)
16.002 – 16.008
(0.6300 – 0.6302)
15.995 – 16.000
(0.6297 – 0.6299)
2/12
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
16.010 – 16.018
(0.6303 – 0.6306)
—
0.20 – 0.65
(0.008 – 0.026)
17.75 – 17.80
(0.699 – 0.701)
55.9 – 56.1
(2.20 – 2.21)
—
Unit: mm (in)
LIMIT
16.040
(0.6315)
3.0
(0.12)
1.0
(0.04)
—
—
0.08
(0.003)
OIL PUMP
ITEM
Oil pressure (at 50 °C, 122 °F)
STANDARD
25 kPa (0.25 kgf/cm
2
, 3.6 psi)
at 6 000 r/min
LIMIT
—
Unit: mm (in)
LIMIT
—
2.42
(0.095)
13.05
(0.514)
0.10
(0.004)
48.2
(1.90)
CLUTCH
ITEM
Clutch cable play
Drive plate thickness
Drive plate claw width
Driven plate distortion
Clutch spring free length
STANDARD
2–3
(0.08 – 0.16)
2.72 – 2.88
(0.107 – 0.113)
13.85 – 13.96
(0.545 – 0.550)
—
50.74
(1.998)
RADIATOR + ENGINE COOLANT
ITEM
Radiator cap valve opening
pressure
Engine coolant type
STANDARD/SPECIFICATION
95 – 125 kPa
(0.95 – 1.25 kgf/cm
2
, 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)
LIMIT
—
—
—
Engine coolant capacity
3/12
TRANSMISSION + DRIVE CHAIN
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratios
STANDARD
3.316 (63/19)
3.769 (49/13)
2.153 (28/13)
1.764 (30/17)
1.470 (25/17)
1.238 (26/21)
1.090 (24/22)
0.10 – 0.30
(0.004 – 0.012)
5.00 – 5.10
(0.197 – 0.201)
4.80 – 4.90
(0.189 – 0.193)
DID 520 DMA4
114 links
—
Low
2nd
3rd
4th
Top
Shift fork to groove clearance
Shift fork groove width
No.1, 2 & 3
No.1, 2 & 3
No.1, 2 & 3
Type
Links
20-pitch
length
Unit: mm (in) Except ratio
LIMIT
—
—
—
—
—
—
—
0.50
(0.020)
—
—
—
—
323.8
(12.75)
—
—
Shift fork thickness
Drive chain
Drive chain slack
Gearshift lever height
34 – 45
(1.4 – 1.8)
10 – 15
(0.4 – 0.6)
(Above the top face of the foot rest)
INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR
ITEM
Injector resistance
Fuel pump discharge amount
Fuel pressure regulator operating
set pressure
SPECIFICATION
10 – 11
at 24 °C (75 °F)
89 ml (3.0/3.1 US/Imp oz) and more
/10 sec.
Approx. 294 kPa (2.94 kgf/cm
2
, 41.81 psi)
NOTE
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
STANDARD/SPECIFICATION
80 – 120
2.8 V and more
0.1 – 0.8
3.5 V and more
4.5 – 5.5 V
0.23 – 4.10 V at idle speed
4.5 – 5.5 V
Closed
Approx. 0.6 V
Opened
Approx. 3.8 V
4.5 – 5.5 V
Approx. 2.58 k at 20 °C (68 °F)
4.5 – 5.5 V
NOTE
4/12
ITEM
IAT sensor resistance
TO sensor resistance
TO sensor voltage
STANDARD/SPECIFICATION
Approx. 2.58 k at 20 °C (68 °F)
16.5 – 22.3 k
Normal
0.4 – 1.4 V
Leaning
3.7 – 4.4 V
0.89 V and more
Battery voltage
NOTE
GP switch voltage
Injector voltage
When
leaning 65°
From 1st to Top
THROTTLE BODY
ITEM
Bore size
I.D. No.
Idle r/min
Throttle cable play
Hot starter lever clearance
SPECIFICATION
44 mm (1.73 in)
49H0
2 100 ± 50 r/min
2 – 4 mm
(0.08 – 0.16 in)
2 – 3 mm
(0.08 – 0.12 in)
Unit: mm (in)
NOTE
ELECTRICAL
ITEM
Ignition timing
Spark plug
Spark performance
CKP sensor resistance
Crankshaft rotation signal sensor
resistance
Charge coil resistance
CKP sensor peak voltage
Crankshaft rotation signal sensor
peak voltage
Ignition coil resistance
STANDARD/SPECIFICATION
8° B.T.D.C. at 2 100 r/min.
Type
NGK: CR8EIA10
Gap
0.9 – 1.0 (0.035 – 0.039)
Over 8 (0.3) at 1 atm.
80 – 120
0.1 – 0.8
1.0 – 2.5
2.8 V and more
3.5 V and more
Primary
Secondary
Ignition coil primary peak voltage
Magneto no-load voltage
(When engine is cold)
Regulated voltage
Engine stop switch resistance
0.01 – 0.11
at
20 °C (68 °F)
4.5 – 6.9 kat 20 °C (68 °F)
175 V and more
95 V (AC) and more at 5 000 r/min
14.0 – 15.0 V at 5 000 r/min
Under 1
R–G
B/R – R/W
Y–Y
+
R–
-
G
+
B/R –
-
R/W
Terminal –
Terminal
Plug cap –
+
Terminal
+
Ground –
-
W/Bl
B/Y – B/W
5/12

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