CFMoto motorcycle CF650NK. Service Manual - part 10

PERIODIC MAINTENANCE 2-7 

Fastener

Torque

Remarks

N·m

kgf·m

ft·lb

Muf

fl

 er Body Mounting Bolt (Rear)

20

2.0

15

Baf

fl

 e Plate Bolts

6

0.60

52in·lb

See text

Clutch

Oil Filler Plug

–

–

–

Finger tighten

Clutch Cover Mounting Bolts

10

1.0

87in·lb

Clutch Spring Bolts

10

1.0

87in·lb

Clutch Hub Nut

132

13.5

98

R

Clutch Lever Clamp Bolts

10

1.0

87in·lb

S

Oil Pump Chain Guide Bolts

12

1.2

106in·lb

L

Clutch Cable Holder Bolts

10

1.0

87in·lb

L

Clutch Cable Clamp Bolt

10

1.0

87in·lb

Engine Lubrication

Drain Bolt

30

3.0

22

Filler Plate Bolts

10

1.0

87in·lb

L

Oil Filter

17

1.75

13

EO,R

Holder Mounting Bolt

25

2.5

18

L

Oil Pan Bolts

12

1.2

106in·lb

Oil Pump Chain Guide Bolts

12

1.2

106in·lb

L

Oil Pipe Plate Bolt

10

1.0

87in·lb

L

Oil Pressure Relief Valve

15

1.5

11

L

Oil Pressure Switch

15

1.5

11

SS

Oil Pump Cover Bolts

10

1.0

87in·lb

L

Lower Fairing Bracket Bolts

12

1.2

106in·lb

L

Oil Pump Sprocket Bolt

12

1.2

106in·lb

L,Lh

Oil Passage Plug

20

2.0

15

L

Engine Removal/Installation

Rear Engine Mounting Nuts

45

4.6

32

S

Engine Mounting Bracket Bolts

25

2.5

18

S

Front Engine Mounting Bolts

45

4.6

32

S

Crankshaft/Transmission

Breather Plate Bolts

10

1.0

87in·lb

L

Crankcase Bolts (M9, L = 113 mm)

44

4.5

32

MO,S

Crankcase Bolts (M9, L = 83 mm)

44

4.5

32

MO,S

Crankcase Bolts (M8, L = 73 mm)

35

3.6

26

MO,S

Crankcase Bolts (M8, L = 60 mm)

35

3.6

26

MO,S

Crankcase Bolts (M8, L = 110 mm)

27.5

2.8

20

S

Crankcase Bolts (M8, L = 50 mm)

27.5

2.8

20

S

Crankcase Bolts (M7)

20

2.0

15

S

Upper Crankcase Bolts

27.5

2.8

20

S

Fastener

Torque

Remarks

N·m

kgf·m

ft·lb

Shift Drum Bearing Holder Screw

5

0.50

43in·lb

L

Connecting Rod Big End Nuts

see text

←

←

MO

Timing Rotor Bolt

40

4.1

30

Oil Pressure Switch

15

1.5

11

SS

Gear Positioning Lever Bolt

12

1.2

106in·lb

L

Shift Shaft Return Spring Pin

29

2.9

22

L

Shift Drum Cam Bolt

12

1.2

106in·lb

L

Neutral Switch

15

1.5

11

Transmission Case Bolts

20

2.0

15

Neutral Switch Holder Screw

5

0.50

43in·lb

L

Shift Shaft Cover Bolts

10

1.0

87in·lb

L(2)

Shift Shaft Cover Screw

5

0.50

43in·lb

L

Wheels/Tires

Front Axle

108

11.0

80

Front Axle Clamp Bolt

34

3.5

25

Rear Axle Nut

108

11.0

80

Final Drive

Engine Sprocket Nut

125

12.7

92

MO

Rear Axle Nut

108

11.0

80

Rear Sprocket Nuts

59

6.0

44

Speed Sensor Bolt

8

0.80

69in·lb

L

Speed Sensor Bracket Bolts

10

1.0

87in·lb

Brakes

Bleed Valve

7.8

0.80

69in·lb

Brake Hose Banjo Bolts

25

2.5

18

Brake Lever Pivot Bolt

1.0

0.10

9in·lb

Si

Brake Lever Pivot Bolt Locknut

5.9

0.60

52in·lb

Brake Pedal Bolt

8.8

0.90

78in·lb

Front Brake Disc Mounting Bolts

27

2.8

20

L

Front Brake Light Switch Screw

1.0

0.10

9in·lb

Front Brake Reservoir Cap Screws

1.0

0.10

9in·lb

Front Caliper Mounting Bolts

34

3.5

25

Front Master Cylinder Clamp Bolts

8.8

0.90

78in·lb

S

Rear Brake Disc Mounting Bolts

27

2.8

20

L

Rear Caliper Mounting Bolts

25

2.5

18

Rear Master Cylinder Mounting Bolts

25

2.5

18

Rear Master Cylinder Push Rod Locknut

18

1.8

13

Suspension

Front Axle Clamp Bolt

34

3.5

25

Front Fork Bottom Allen Bolts

30

3.1

22

L

2-8 PERIODIC MAINTENANCE

Fastener

Torque

Remarks

N·m

kgf·m

ft·lb

Front Fork Clamp Bolts (Lower)

20

2.0

15

AL

Front Fork Clamp Bolts (Upper)

20

2.0

15

Front Fork Top Plugs

25

2.5

18

Rear Shock Absorber Bolt

59

6.0

44

Rear Shock Absorber Nut

59

6.0

44

Swingarm Pivot Shaft Nut

180

—

—

Steering

Front Fork Clamp Bolts (Lower)

20

2.0

15

AL

Front Fork Clamp Bolts (Upper)

20

2.0

15

Handlebar Holder Bolts

25

2.5

18

S

Left Switch Housing Screws

3.5

0.36

31 in·lb

Right Switch Housing Screws

3.5

0.36

31 in·lb

Steering Stem Head Bolt

108

11.0

80

Steering Stem Nut

20

2.0

15

Frame

Footrest Stay Bolts

34

3.5

25

Front Fender Bolts

3.9

0.40

35 in·lb

Front Fender Bracket Bolts

8.8

0.90

78 in·lb

L

Front Turn Signal Light Mounting Screws

1.2

0.12

11 in·lb

Grab Rail Mounting Bolts

25

2.5

18

Lower Fairing Mounting Bolts

8.8

0.90

78 in·lb

Seat Lock Mounting Screws

1.2

0.12

11 in·lb

Sidestand Bolt

44

4.5

32

Sidestand Switch Bolt

8.8

0.90

78 in·lb

L

Electrical System

Alternator Cover Bolts

10

1.0

87 in·lb

Alternator Lead Holding Plate Bolt

10

1.0

87 in·lb

L

Alternator Rotor Bolt

155

15.8

114

MO

Crankshaft Position Sensor Bolts

6.0

0.60

53 in·lb

Engine Ground Cable Terminal Bolt

9.8

1.0

87 in·lb

Front Brake Light Switch Screw

1.2

0.12

11 in·lb

Front Turn Signal Light Mounting Screws

1.2

0.12

11 in·lb

Left Switch Housing Screws License

3.5

0.36

31 in·lb

Plate Light Cover Screws License

0.90

0.090

8 in·lb

Plate Light Mounting Screws Meter

1.2

0.12

11 in·lb

Neutral Switch

15

1.5

11

Oil Pressure Switch

15

1.5

11

SS

Oxygen Sensor

60

6.10

44.3

Regulator/Recti

fi

 er Bolts

8.8

0.90

78 in·lb

Right Switch Housing Screws

3.5

0.36

31 in·lb

Sidestand Switch Bolt

8.8

0.90

78 in·lb

L

Spark Plugs

15

1.5

11

 PERIODIC MAINTENANCE 2-9

Fastener

Torque

Remarks

N·m

kgf·m

ft·lb

Speed Sensor Bolt

8.0

0.80

69in·lb

L

Starter Motor Cable Terminal Nut

6.0

0.60

53in·lb

Starter Motor Mounting Bolts

10

1.0

87in·lb

L

Stator Coil Bolts

12

1.2

106in·lb

L

Timing Rotor Bolt

40

4.1

30

Coolant Temp. Sensor

12.0

1.2

106in·lb

The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. 

Use this table for only the bolts and nuts which do not require a speci

fi

 c torque value. All of the values are 

for use with dry solvent-cleaned threads. 

Basic Torque for General Fasteners

Threads Diameter

(mm)

Torque

N·m

kgf·m

ft·lb

5

3.4-4.9

0.35-0.50

30-43in·lb

6

5.9-7.8

0.60-0.80

52-69in·lb

8

14-19

1.4-1.9

10.0-13.5

10

25-34

2.6-3.5

19.0-25

12

44-61

4.5-6.2

33-45

14

73-98

7.4-10.0

54-72

16

115-155

11.5-16.0

83-115

18

165-225

17.0-23.0

125-165

20

225-325

23.0-33.0

165-240

2-10 PERIODIC MAINTENANCE

 PERIODIC MAINTENANCE 2-11

Specifi cations and Service Limit

  Item

Standard

Service Limit

EFI

 Throttle Grip Free Play 
 Idle Speed
 Air Filter Element

 2~3mm(0.08~0.12in.)                         
 1300±130r/min(rpm)

 Polyurethane Foam

Cooling System

Coolant:

Type(recommended) 
Color

Mixed Ratio
Freezing Point
Total Amount

Permanent type of antifreeze
Green

Soft water 50%, Coolant 50%

–35°C(–31°F)

1.6L(1.7USqt)

Engine Top End

Valve Clearance

Exhaust
Intake

0.20~0.26mm(0.0078~0.0102in.)

 0.08~0.13mm(0.0031~0.0051in.)

– – –
– – –

Clutch

Clutch Lever Free Play

2 ~3mm(0.08~0.12in.)

– – –

 Engine Lubrication System

 Engine Oil:
 Type

 Viscosity
 Capacity

 Level

API  SG or higher

SAE 15W-40
2.0L(1.8USqt)( when 

fi

 lter is not replaced)

2.2L(2.0USqt)( when 

fi

 lter is replaced)

2.6L(2.5USqt)( when engine is completely dry)
Between upper and lower level lines
(after idling or running)

– – –

– – –
– – –
– – –
– – –
– – –

Wheels/Tirs

Tread Depth:          

 Front 

 Rear

 Air Pressure (when Cold):
 Front

 Rear

4.5mm(0.18in.)

5.5mm(0.22in.)

280kPa(2.80kgf/cm

2

,39.8psi)

280kPa(2.80kgf/cm

2

,39.8psi)

0.8~1.0mm

0.8~1.0mm

– – –

– – –

Item

Standard 

Service Limit

Final Drive

Drive Chain Slack

Drive Chain Wear (20-link

Length)

Standard Chain:

Make

Type

Link

30~40mm(1.2~1.6in.)

317.5~318.2mm(12.50 12.53in.)

Japan  RK

520×S01

114 links

– – –

323mm(12.7in.)

– – –
– – –
– – –

Brakes

 

     Grade

B r a k e   P a d   L i n i n g  

Thickness:

Front

Rear

Brake Light Timing:

Front 

Rear

DOT4 or DOT5

4mm(0.15in.)

5mm(0.196in.)

Pulled ON

ON after about 10 mm (0.39 in.)

of pedal travel 

– – –

1mm(0.04in.)

1mm(0.04in.)

– – –

Electrical System

    Spark Plug Gap

0.7~0.9mm(0.027~0.035in.)

– – –

Brake Fluid:

2-12 PERIODIC MAINTENANCE

PERIODIC MAINTENANCE 2-13

Special Tools

Inside Circlip Pliers

Extension Tube

Steering Stem Nut Wrench

 Pilot Screw Adjuster,E

Oil Filter Wrench

2-14  PERIODIC MAINTENANCE

Electronic Fuel Injection

Air Filter Element Cleaning

                               

NOTE

O

 

In dusty areas,the element should be cleaned

   frequently than the recommended interval.

O

 

After rding through rain or on muddily road,element

   should be cleaned immediately.

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

 

Remove:

   Fuel tank(see Fuel Tank Removal in the Fuel
   System);



 Remove air filter element screw;



 Remove air filter element comp..



 Remove the holder.



 Remove element

NOTE

O 

The wire screen is fastened with an adhesive for

   the shaded portion.Do not remove the wire screen.

Screw

!

Element

Element Comp.

WARNING

PERIODIC MAINTENANCE 2-15

WARNING

Clean the element in a well-ventilated area,

and make sure that there are no sparks or

flame anywhere near the working area.

Because of the danger of highly flammable

liquids,do not use gasoline or a low-flash

point solvent to clean the element.

Throttle Control System Inspection



 Check that the throttle grip moves smoothly from

   full open to close [A], and the throttle closes
   quickly and completely by the return spring in all
   steering positions.

If the throttle grip doesn’t return properly, check

   the throttle cable routing, grip free play, and cable
   damage. Then lubricate the throttle cable.



 Check the throttle grip free play [A].

If the free play is incorrect, adjust the throttle

   cable.

Throttle Grip Free Play

    Standard: 2~3 mm(0.08~0.12in.)



 Clean the element element [A] in a bath of high-

   flash point solvent, and then dry it with com-
   pressed air or by shaking it.



 After cleaning, saturate a clean, lint-free towel with

   SE, SF, or SG class SAE 30 oil and apply the oil
   to the element by tapping the element outside
   with the towel.



 Visually check the element for tears or breaks.



 If the element has any tears or breaks, replace

   the element.



 lnstall the element unit [A] with the foam element

   outside (gray) facing down.

!

2-16  PERIODIC MAINTENANCE

If necessary,adjust the throttle cable as follows.



 Loosen the locknut [A] at the upper end of the

   accelerate cable.



 Turn the adjuster [B] in completely so as to give

   the throttle grip plenty of play.



 Loosen the locknut [A] at the middle of the

   decelerate cable.



 Turn the adjuster [B] until there is no play when

   the throttle grip is completely closed.



 Tighten the locknut.



 Turn the accelerate cable adjuster until the proper

   amount of throttle grip free play is obtained.



 Tighten the locknut.

Idle Speed Inspection



 Start the engine and warm it up thoroughly.

   With the engine idling, turn the handlebar to both
   sides [A].

If handlebar movement changes the idle speed,

   the throttle cables may be improperly adjusted or
   incorrectly routed or damaged. Be sure to correct
   any of these conditions before diding.

WARNING

Operation with improperly adjusted,incorrect-

ly routed or damaged cables could result in

an unsafe riding condition.



 Check the idle speed.

If the idle speed is out of the specified range,

   check throttle body for air leaks and calibration.

Idle Speed

   Standard:   1300

130 r/min(rpm)

!

PERIODIC MAINTENANCE 2-17

Fuel Line Inspection (fuel leak, damage,

installation condition)

O

 The fuel line is designed to be used throughout

   the motorcycle’s life without any maintenance.
   However, if the motorcycle is not properly
   handled, the high pressure inside the fuel line can
   cause fuel to leak [A] or the line to burst. Re-
   move the fuel tank (see Fuel Tank Removal in the
   Fuel System chapter) and check the fuel line.

Replace the fuel line if any fraying, cracks [B] or

   bulges [C] are noticed.



 Check the line if it has been sharply bent or

   kinked.
   Hose Joints [A]
   Fuel Line [B]



 Check that the hose joints are securely connected.

O  

Push and pull [A] the hose joint [B] back and forth

   more than two times, and make sure it is locked.

If it is not locked,reinstall the hose joint.

WARNING

Make sure the hose joint is installed correctly

on the delivery pipe by sliding the joint, or

 the fuel could leak.

!

2-18  PERIODIC MAINTENANCE

Cooling System

Coolant Level Inspection

NOTE

O

 

Check the level when the engine is cold (room or

   ambient temperature).



 Check the coolant level in the reserve tank [A]

   with the motorcycle held perpendicular (Do not
   use the sidestand).

If the coolant level is lower than the “L” level line

   [B], remove the right center fairing (see Center
   Fairing Removal in the Frame chapter) and un-
   screw the reserve tank cap, and add coolant to
   the “F” level line [C].
   “L”: low
   “F”: full

N

O

I

T

U

A

C

For refilling,add the specified mixture of

coolant and soft water.Adding water alone

dilutes the coolant and degrades its anticorro-

sion properties.The diluted coolant can attack

the aluminum engine parts.In an emergency,

soft water alone can be added.But the diluted

coolant must be returned to the correct mix-

ture ratio within a few days.If coolant must be

added often or the reservoir tank has run

completely dry,there is a probably leakage in

the cooling system.Check the system for leaks.

Coolant ruins paited surfaces.Immediately

wash away any coolant that spills on the

frame,engine,wheels or other painted parts.

Radiator Hose Damage and installation condition

inspection

O

 The high pressure inside the radiator hose and

   pipe can cause coolant to leak [A] or the hose to
   burst if the line is not properly maintained.



 Visually inspect the hoses for signs of

   deterioration. Squeeze the hoses.A hose should
   not be hard and brittle,nor should it be soft or
   swollen.

Replace the hose if any fraying, cracks [B] or

   bulges [C] are noticed.



 Check that the hoses are securely connected and

   clamps are tightened correctly.

Torque-Radiator Hose Clamp Screws:

   2.5 N

m(0.25 kgf

m)

PERIODIC MAINTENANCE 2-19

Engine Top End

Valve Clearance Inspection

NOTE

O

 

Valve clearance must be checked and adjusted

   when the engine is cold (room temperature).



 Remove the cylinder head cover (see Cylinder

   Head Cover Removal in the Engine Top End chapter)



 Unscrew the upper [A] and lower [B] caps on the

   clutch cover.



 Check the valve clearance when the pistons are at

   TDC.

O 

The pistons are numbered beginning with the engine

   left side.



 Using a wrench [A] on the crankshaft rotation bolt,

   turn the crankshaft clockwise until the “1/T” mark
   on the timing rotor is aligned with the notch [B] in
   the edge of the upper hole in the clutch cover for #1
   piston and “2/T” mark for #2 piston.

   1/T Mark [A]
   2/T Mark [B]
   Hole [C] of Upper Cap
   Notch [D] in Edge of Upper Hole



 Using the feeler gauge [A], measure the valve

   clearance between cam and valve lifter.

Valve Clearance

    Standard:

        Exhaust: 0.22~0.31 mm (0.0087~0.0122 in.)

        Intake:    0.15~0.21 mm (0.0059~0.0083 in.)

2-20  PERIODIC MAINTENANCE

Valve Clearance Measuring Position

 

#1 Piston

TDC at End of Compression Stroke

Intake

valve clearances of #1 piston,and Exhaust valve

clearances of #1 piston

NOTE

O 

Check the valve clearance using this method only.

   Checking the clearance at any other cam position

   may result in improper valve clearance.

Valve Clearance Measuring Position #2 Piston

TDC at End of Compression Stroke

Intake valve

clearances of #2 piston,and Exhaust valve

clearances of #2 piston

If the valve clearance is not within the specified

   range,first record the clearance,and adjust it.

Valve Clearance Adjustment



 To change the valve clearance,remove the cam

   shaft chain tensioner,camshafts and valve lifters.
   Replace the shim with one of a different thickness.

NOTE

O

 

Mark and record the valve lifter and shim location

   so they can be reinstalled in their original positions.

O

 

If there is no clearance,select a shim which is sev-

   eral sizes smaller and then measure the clearance.



 To select a new shim which brings the valve

   clearance within the specified range, refer to the
   Valve Clearance Adjustment Charts.



 Apply a thin coat of molybdenum disulfide grease

   to the valve lifters.



 Install the camshafts. Be sure to time the cam

   shafts properly (see Camshaft Installation in the
   Engine Top End chapter).



 Remeasure any valve clearance that wasadjusted.

   Readjust if necessary.

 PERIODIC MAINTENANCE 2-21

Valve Adjustment Chart(Intake Valve)

　

  Present Shim                        Example

Mark

320 322 324 326 328 330 332 334 336 338 340 342 344 346 348 350 352 354 356 358 360 362 364

366

Thickness

3.2 3.22 3.24 3.26 3.28 3.3 3.32 3.34 3.36 3.38 3.4 3.42 3.44 3.46 3.48 3.5 3.52 3.54 3.56 3.58 3.6 3.62 3.64

3.66

　

                                     Example              V

alve Clearance Measurement

0

～

0.01

—

—

—

—

—

3.2 3.22 3.24 3.26 3.28 3.3 3.32 3.34 3.36 3.38 3.4 3.42 3.44 3.46 3.48 3.5 3.52 3.54

3.56

0.02

～

0.03

—

—

—

—

3.2 3.22 3.24 3.26 3.28 3.3 3.32 3.34 3.36 3.38 3.4 3.42 3.44 3.46 3.48 3.5 3.52 3.54 3.56

3.58

0.04

～

0.05

—

—

—

3.2 3.22 3.24 3.26 3.28 3.3 3.32 3.34 3.36 3.38 3.4 3.42 3.44 3.46 3.48 3.5 3.52 3.54 3.56 3.58

3.6

0.06

～

0.07

—

—

3.2 3.22 3.24 3.26 3.28 3.3 3.32 3.34 3.36 3.38 3.4 3.42 3.44 3.46 3.48 3.5 3.52 3.54 3.56 3.58 3.6

3.62

0.08

～

0.13

Speci

fi

 ed Clearance/No Change Required

0.14

～

0.15 3.22 3.24 3.26 3.28 3.3 3.32 3.34 3.36 3.38 3.4 3.42 3.44 3.46 3.48 3.5 3.52 3.54 3.56 3.58 3.6 3.62 3.64 3.66

3.68

0.16

～

0.17 3.24 3.26 3.28 3.3 3.32 3.34 3.36 3.38 3.4 3.42 3.44 3.46 3.48 3.5 3.52 3.54 3.56 3.58 3.6 3.62 3.64 3.66 3.68

3.7

0.18

～

0.19 3.26 3.28 3.3 3.32 3.34 3.36 3.38 3.4 3.42 3.44 3.46 3.48 3.5 3.52 3.54 3.56 3.58 3.6 3.62 3.64 3.66 3.68 3.7

3.72

0.20

～

0.21 3.28 3.3 3.32 3.34 3.36 3.38 3.4 3.42 3.44 3.46 3.48 3.5 3.52 3.54 3.56 3.58 3.6 3.62 3.64 3.66 3.68 3.7 3.72

3.74

0.22

～

0.23

3.3 3.32 3.34 3.36 3.38 3.4 3.42 3.44 3.46 3.48 3.5 3.52 3.54 3.56 3.58 3.6 3.62 3.64 3.66 3.68 3.7 3.72 3.74

3.76

0.24

～

0.25 3.32 3.34 3.36 3.38 3.4 3.42 3.44 3.46 3.48 3.5 3.52 3.54 3.56 3.58 3.6 3.62 3.64 3.66 3.68 3.7 3.72 3.74 3.76

3.78

0.26

～

0.27 3.34 3.36 3.38 3.4 3.42 3.44 3.46 3.48 3.5 3.52 3.54 3.56 3.58 3.6 3.62 3.64 3.66 3.68 3.7 3.72 3.74 3.76 3.78

3.8

0.28

～

0.29 3.36 3.38 3.4 3.42 3.44 3.46 3.48 3.5 3.52 3.54 3.56 3.58 3.6 3.62 3.64 3.66 3.68 3.7 3.72 3.74 3.76 3.78 3.8

3.82

0.30

～

0.31 3.38 3.4 3.42 3.44 3.46 3.48 3.5 3.52 3.54 3.56 3.58 3.6 3.62 3.64 3.66 3.68 3.7 3.72 3.74 3.76 3.78 3.8 3.82

3.84

0.32

～

0.33

3.4 3.42 3.44 3.46 3.48 3.5 3.52 3.54 3.56 3.58 3.6 3.62 3.64 3.66 3.68 3.7 3.72 3.74 3.76 3.78 3.8 3.82 3.84

3.86

0.34

～

0.35 3.42 3.44 3.46 3.48 3.5 3.52 3.54 3.56 3.58 3.6 3.62 3.64 3.66 3.68 3.7 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3.86

3.88

0.36

～

0.37 3.44 3.46 3.48 3.5 3.52 3.54 3.56 3.58 3.6 3.62 3.64 3.66 3.68 3.7 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88

3.9

0.38

～

0.39 3.46 3.48 3.5 3.52 3.54 3.56 3.58 3.6 3.62 3.64 3.66 3.68 3.7 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9

3.92

0.40

～

0.41 3.48 3.5 3.52 3.54 3.56 3.58 3.6 3.62 3.64 3.66 3.68 3.7 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92

3.94

0.42

～

0.43

3.5 3.52 3.54 3.56 3.58 3.6 3.62 3.64 3.66 3.68 3.7 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94

3.96

0.44

～

0.45 3.52 3.54 3.56 3.58 3.6 3.62 3.64 3.66 3.68 3.7 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96

3.98

0.46

～

0.47 3.54 3.56 3.58 3.6 3.62 3.64 3.66 3.68 3.7 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98

4

0.48

～

0.49 3.56 3.58 3.6 3.62 3.64 3.66 3.68 3.7 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98

4

4.02

0.50

～

0.51 3.58 3.6 3.62 3.64 3.66 3.68 3.7 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98

4

4.02

4.04

0.52

～

0.53

3.6 3.62 3.64 3.66 3.68 3.7 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98

4

4.02 4.04

4.06

0.54

～

0.55 3.62 3.64 3.66 3.68 3.7 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98

4

4.02 4.04 4.06

4.08

0.56

～

0.57 3.64 3.66 3.68 3.7 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98

4

4.02 4.04 4.06 4.08

4.1

0.58

～

0.59 3.66 3.68 3.7 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98

4

4.02 4.04 4.06 4.08 4.1

4.12

0.60

～

0.61 3.68 3.7 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98

4

4.02 4.04 4.06 4.08 4.1 4.12

4.14

0.62

～

0.63

3.7 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98

4

4.02 4.04 4.06 4.08 4.1 4.12 4.14

4.16

0.64

～

0.65 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98

4

4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16

4.18

0.66

～

0.67 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98

4

4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18

0.68

～

0.69 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98

4

4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18

0.70

～

0.71 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98

4

4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18

0.72

～

0.73

3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98

4

4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18

0.74

～

0.75 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98

4

4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18

0.76

～

0.77 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98

4

4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18

0.78

～

0.79 3.86 3.88 3.9 3.92 3.94 3.96 3.98

4

4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18

0.80

～

0.81 3.88 3.9 3.92 3.94 3.96 3.98

4

4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18

0.82

～

0.83

3.9 3.92 3.94 3.96 3.98

4

4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18

0.84

～

0.85 3.92 3.94 3.96 3.98

4

4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18

0.86

～

0.87 3.94 3.96 3.98

4

4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18

0.88

～

0.89 3.96 3.98

4

4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18

0.90

～

0.91 3.98

4

4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18

0.92

～

0.93

4

4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18

0.94

～

0.95 4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18

0.96

～

0.97 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18

0.98

～

0.99 4.06 4.08 4.1 4.12 4.14 4.16 4.18

1.00

～

1.01 4.08 4.1 4.12 4.14 4.16 4.18

1.02

～

1.03

4.1 4.12 4.14 4.16 4.18

1.04

～

1.05 4.12 4.14 4.16 4.18

1.06

～

1.07 4.14 4.16 4.18

1.08

～

1.09 4.16 4.18

1.10

～

1.11 4.18

Valve Clearance Adjustment Chart(Intake Valve)

   Present Shim

Mark

368 370 372 374 376 378 380 382 384 386 388 390 392 394 396 398 400 402 404 406 408 410 412 414 416

418

Thickness

3.68 3.7 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98

4

4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16

4.18

Clearance Measurement

0

~

0.01

3.58 3.6 3.62 3.64 3.66 3.68 3.7 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98 4 4.02 4.04 4.06

4.08

0.02

~

0.03

3.6 3.62 3.64 3.66 3.68 3.7 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98 4 4.02 4.04 4.06 4.08

4.1

0.04

~

0.05 3.62 3.64 3.66 3.68 3.7 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98 4 4.02 4.04 4.06 4.08 4.1

4.12

0.06

~

0.07 3.64 3.66 3.68 3.7 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98 4 4.02 4.04 4.06 4.08 4.1 4.12

4.14

0.08

~

0.13

Speci

fi

 ed Clearance/No Change Required

0.14

~

0.15

3.7 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98

4

4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18

0.16

~

0.17 3.72 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98

4

4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18

0.18

~

0.19 3.74 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98

4

4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18

0.20

~

0.21 3.76 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98

4

4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18

0.22

~

0.23 3.78 3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98

4

4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18

0.24

~

0.25

3.8 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98

4

4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18

0.26

~

0.27 3.82 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98

4

4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18

0.28

~

0.29 3.84 3.86 3.88 3.9 3.92 3.94 3.96 3.98

4

4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18

0.30

~

0.31 3.86 3.88 3.9 3.92 3.94 3.96 3.98

4

4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18

0.32

~

0.33 3.88 3.9 3.92 3.94 3.96 3.98

4

4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18

0.34

~

0.35

3.9 3.92 3.94 3.96 3.98

4

4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18

0.36

~

0.37 3.92 3.94 3.96 3.98

4

4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18

0.38~0.39 3.94 3.96 3.98

4

4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18

0.40

~

0.41 3.96 3.98

4

4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18

0.42

~

0.43 3.98

4

4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18

0.44

~

0.45

4

4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18

0.46

~

0.47 4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18

0.48

~

0.49 4.04 4.06 4.08 4.1 4.12 4.14 4.16 4.18

0.50

~

0.51 4.06 4.08 4.1 4.12 4.14 4.16 4.18

0.52

~

0.53 4.08 4.1 4.12 4.14 4.16 4.18

0.54

~

0.55

4.1 4.12 4.14 4.16 4.18

0.56

~

0.57 4.12 4.14 4.16 4.18

0.58

~

0.59 4.14 4.16 4.18

0.60

~

0.61 4.16 4.18

0.62

~

0.63 4.18

1.Measure the clearance (when engine is cold).

2.Check present shim size.

   Example: Present shim is 3.50 mm.

   Measured clearance is 0.25 mm.

   Replace 3.50 mm shim with 3.62 mm shim.

   Remeasure the valve clearance and readjust if necessary.

2-22 PERIODIC MAINTENANCE