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FAQ2017-03-19T18:08:19-07:00
Piston Clearances2020-05-19T14:46:41-07:00

We measure our clearances 0.400″ from the bottom of the skirt. What we have found works best is to find different pieces of paper in varying thickness, measure with a micrometer and write the thickness on the paper. If the piston falls through it’s got more clearance. If it stops in the bore it’s about right, and if it must be pushed through it needs more clearance to match the paper.

Bore Cast Iron Liner Aluminium Liner Ring End Gap Min. Head Valve – Intake Valve – Exhaust
89mm 0.0015” – 0.002” 0.016” 0.055″ – 0.060″ 0.060″ 0.090″
94mm 0.0015” – 0.002” 0.018″ 0.060″ – 0.065″ 0.060″ 0.090″
97mm 0.0015” – 0.002” 0.019” 0.065″ – 0.070″ 0.060″ 0.090″
98mm 0.004” 0.019” 0.065″ – 0.070″ 0.060″ 0.090″
99mm 0.0045” 0.020” 0.065″ – 0.070″ 0.060″ 0.090″
100mm 0.005″ 0.022” 0.065″ – 0.070″ 0.060″ 0.090″
102mm 0.022” 0.065″ – 0.070″ 0.060″ 0.090″
103.1mm 0.0055” 0.022” – 0.024” 0.065″ – 0.070″ 0.060″ 0.090″
Cam Specs2020-05-19T14:46:57-07:00

With any of the engines, the cam bolt and lock washer should be replaced
frequently. Be sure to use a liberal amount of blue Loctite on the cam bolt and
torque to the specifications in the manual.

Timing checked at 0.040 in. (1 mm) lift, 0.00 clearance
Running clearance 0.004 in. (0.1 mm)

Cam Lift Duration Open Close
660 7.9mm 225° 2.5° BTDC
42.5° BBDC
42.5° ABDC
2.5° ATDC
IN
EX
665 7.8mm
7.87mm
240°
225°
4° BTDC
36.5° BBDC
56° ABDC
8.5° ATDC
IN
EX
667 229°
670 8.9mm 261° 13.5° BTDC
90.5° BBDC
67.5° ABDC
20.5° ATDC
IN
EX
675 9.65mm
9.56mm
297°
285°
45.5° BTDC
74.5° BBDC
71.5° ABDC
30.5° ATDC
IN
EX
700 220°
240°
800 9.3mm 249° 12° BTDC
55° BBDC
57° ABDC
14° ATDC
IN
EX
802 249°
260°
805 9.64mm 248° 12° BTDC
54° BBDC
56° ABDC
14° ATDC
IN
EX
860 10.55mm 292° 44° BTDC
72° BBDC
68° ABDC
40° ATDC
IN
EX
865 9.67mm 269° 20° BTDC
65° BBDC
69° ABDC
24° ATDC
IN
EX
MC x6 0.450″ 264° 24° BTDC
60° BBDC
60° ABDC
24° ATDC
IN
EX
MC x11 0.420″
0.405″
278°
274°
33° BTDC
66° BBDC
65° ABDC
31° ATDC
IN
EX
MC x20 0.450″
0.422″
290°
292°
42.5° BTDC
63.5° BBDC
67.5° ABDC
38.5° ATDC
IN
EX
Ignition Resistances2020-05-19T14:47:00-07:00
Part Wire Coler Resistance
Trigger Coil
High Speed Black -> Pink 12-20 Ω
Low Speed Black -> Blue 120-180 Ω
Stator
Low Speed Charging Coil Black -> Brown 230-350 Ω
High Speed Charging Coil Brown -> Red 4-6 Ω
Lighting Coils White -> Orange 0.6-0.9 Ω
White -> Green 0.54-0.8 Ω
Green -> Orange 0.8-1.6 Ω
Ignition Coil
Primary Winding Core -> Orange 0.95-1.1 Ω
Secondary Winding High Tension Wire -> Black 11-12k Ω
Bottom End Clearances2020-05-19T14:47:03-07:00

Crankshaft

Width (Nominal): 74.95mm (2.950″) to 75.05mm (2.954″)
Runout: Max 0.05mm (0.002″)
End Play: 0.1mm (0.004″) to 0.4mm (0.0157″)

Connecting Rod

Radial Play: Max 0.05mm (0.002″)
Axial Play: 0.60mm (0.0236″) to 0.93mm (0.0356″)
Axial Wear Limit: Max 1.4mm (0.0551″)

Small End ID: 22.02mm (0.8669″) to 22.04mm (0.8677″)
Piston Pin OD: 22mm (0.8661) +0.0mm (0.00″) / -0.004mm (0.0015″)
Clearance: 0.02mm (0.0007″) to 0.044mm (0.0017″)

Balancer

End Play: 0.1mm (0.004″) to 0.2mm (0.008″)

Oil Pump

Rotor Tip: 0.01mm (0.0003″) to 0.1mm (0.0039″)
Housing: 0.11mm (0.0043″) to 0.19mm (0.0074″)
End Clearance: 0.02mm (0.0008″) to 0.09 (0.0035″)

Transmission Shaft

End Play: 0.1mm (0.004″) to 0.2mm (0.008″)

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