3
Torque Specifications
NOTE: Torque specifications have the following tol-
erances:
CYLINDER, PISTON, AND RINGS
Piston Skirt/Cylinder Clearance 0.60-0.73 mm
Piston Diameter 15 mm from Skirt End 88.96-88.98 mm
Piston Ring Free End Gap (max) (1st)
(2nd)
8.0 mm
8.3 mm
Bore x Stroke 89.0 x 71.2 mm
Cylinder Trueness (max) 0.01 mm
Piston Ring End Gap — Installed (min) 0.30 mm
Piston Ring to Groove Clearance (max)
(1st/2nd)
0.06 mm
Piston Ring Groove Width (1st)
(2nd)
(oil)
1.01-1.03 mm
1.21-1.23 mm
2.01-2.03 mm
Piston Ring Thickness (1st)
(2nd)
1.01-1.03 mm
1.17-1.19 mm
Piston Pin Bore (max) 20.008 mm
Piston Pin (min) 19.994 mm
CRANKSHAFT
Connecting Rod (small end) (max) 20.021 mm
Connecting Rod (big end side-to-side) 0.10-0.55 mm
Connecting Rod (big end width) 21.95-22.00 mm
Connecting Rod (small end deflection)
(max)
3.0 mm
Crankshaft (web-to-web) 60.9 mm
Crankshaft Runout (max) 0.03 mm
CAMSHAFT AND CYLINDER HEAD
Cam Lobe Height (min)(intake)
(exhaust)
34.71 mm
34.48 mm
Camshaft Journal Holder (right & center)
Inside Diameter (left)
22.01-22.04 mm
17.51-17.54 mm
Camshaft Journal Outside(right & center)
Diameter (left)
17.466-17.480 mm
21.959- 21.980 mm
Camshaft Runout (max) 0.03 mm
Cylinder Head/Cover Distortion (max) 0.05 mm
Torque (ft-lb) Tolerance
0-15 ±20%
16-39 ±15%
40+ ±10%
Part Part Bolted to
Torque
ft-lb N-m
EXHAUST COMPONENTS
Exhaust Pipe Cylinder Head 15 20.4
Spark Arrester Muffler 50 in.-lb 5
O2 Sensor Exhaust Pipe 18.5 25
BRAKE COMPONENTS
Brake Disc (Front/Rear)** Hub 25 34
Brake Hose Caliper 25 34
Brake Hose Master Cylinder 25 34
Master Cylinder Frame 15.5 21
Caliper**** Knuckle 20 27.2
Brake Pedal Frame 15.6 21.1
Rear Caliper Bracket Gear Case 32 45
Banjo Bolt Brakeline Junction 18 25
ELECTRICAL COMPONENTS
Coil* Bracket 8 11
STEERING COMPONENTS
Steering Wheel** Steering Shaft 25 34
Rack and Pinion Assembly Frame 35 48
Tie Rod End** Knuckle 30 41
Tie Rod Tie Rod End 8 11
Intermediate Shaft Steering Column 15 20.4
Intermediate Shaft Rack 15 20.4
Tilt Assembly Steering Support 23 31.3
Gas Spring Steering Support 15 20.4
CHASSIS/ROPS ASSEMBLY
Shift Axle Support Frame 48 in.-lb 5
Front/Rear ROPS Tube Arm Rest/Steering Support 47 64
Top ROPS Support Front/Rear ROPS Tubes 47 64
Rear ROPS Tube Lower ROPS Support 47 64
Shift Lever/Lever Assembly Frame 15 20.4
Shift Cable Mounting/Adjuster Shift Cable 20 27
Seat Belt Loop ROPS 42 57
Side Panel/Spacer Cargo Box Frame 25 34
Tilt Pivot Bushing Cargo Box Frame 15 20.4
Latch Striker Cargo Box Liner 60 in.-lb 7
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