Engine Electrical

Item | Measurement | Qualification | Standard or New | Service Limit
--- | --- | --- | --- | ---
Drive belt | Tension |  | Auto-tensioner
Alternator | Output | At 13.5 V and normal engine temperature | 105 A
Coil (rotor) resistance | At 20 °C (68 °F) | 2.5 Ω
Slip ring O.D. |  | 14.4 mm (0.57 in.) | 14.0 mm (0.55 in.)
Brush length |  | 10.5 mm (0.41 in.) | 1.5 mm (0.06 in.)
Brush spring tension |  | 3.3−4.1 N (0.34−0.42 kgf, 0.7−0.9 lbf)
Starter | Output |  | 2.0 kW
Commutator mica depth |  | 0.5 mm (0.020 in.) | 0.20 mm (0.008 in.)
Commutator runout |  | 0.05 mm (0.002 in.) max. | 0.1 mm (0.004 in.)
Commutator O.D. |  | 31.9−32.1 mm (1.256−1.263 in.) | 31.4 mm (1.24 in.)
Brush length |  | 18.0 mm (0.7 in.) | 11.0 mm (0.4 in.)

Engine Assembly

Item | Measurement | Qualification | Standard or New
--- | --- | --- | ---
Compression | Pressure Check the engine with the starter cranking | Minimum | 2.4 MPa (24.5 kgf/cm 2 , 348 psi)
Maximum variation | 200 kPa (2.0 kgf/cm 2 , 28 psi)

Cylinder Head

Item | Measurement | Qualification | Standard or New | Service Limit
--- | --- | --- | --- | ---
Head | Warpage |  | ——— | 0.05 mm (0.002 in.)
Height |  | 114.95−115.05 mm (4.526−4.530 in.) | ———
Camshaft | End play |  | 0.05−0.15 mm (0.002−0.006 in.) | 0.16 mm (0.0063 in.)
Camshaft-to-holder oil clearance | No. 1 journal | 0.0012−0.0027 mm (0.00005−0.00011 in.) | 0.08 mm (0.003 in.)
No. 2, 3, 4, 5 journals | 0.0020−0.0035 mm (0.00008−0.00014 in.) | 0.10 mm (0.004 in.)
Total runout |  | 0.03 mm (0.001 in.) max. | 0.04 mm (0.002 in.)
Cam lobe height | Intake A | 36.433 mm (1.4462 in.) | ———
Intake B | 35.362 mm (1.3922 in.) | ———
Exhaust | 35.539 mm (1.3992 in.) | ———
Valve | Clearance (cold) |  | Auto adjust
Stem O.D. | Intake | 5.480−5.490 mm (0.2157−0.2161 in.) | 5.450 mm (0.2146 in.)
Exhaust | 5.450−5.460 mm (0.2146−0.2150 in.) | 5.420 mm (0.2134 in.)
Stem-to-guide clearance | Intake | 0.020−0.050 mm (0.0008−0.0020 in.) | 0.08 mm (0.003 in.)
Exhaust | 0.050−0.080 mm (0.0020−0.0031 in.) | 0.11 mm (0.004 in.)
Valve seat | Width | Intake | 1.25−1.55 mm (0.049−0.061 in.) | 2.00 mm (0.079 in.)
Exhaust | 1.25−1.55 mm (0.049−0.061 in.) | 2.00 mm (0.079 in.)
Stem installed height | Intake | 40.2−40.4 mm (1.58−1.59 in.) | ———
Exhaust | 40.2−40.4 mm (1.58−1.59 in.) | ———
Valve spring | Free length | Intake | 43.54 mm (1.714 in.) | ———
Exhaust | 43.54 mm (1.714 in.) | ———
Valve guide | I.D. | Intake | 5.51−5.53 mm (0.217−0.218 in.) | 5.55 mm (0.219 in.)
Exhaust | 5.51−5.53 mm (0.217−0.218 in.) | 5.55 mm (0.219 in.)
Installed height | Intake | 14.5−15.5 mm (0.571−0.610 in.) | ———
Exhaust | 14.5−15.5 mm (0.571−0.610 in.) | ———

Engine Block

Item | Measurement | Qualification | Standard or New | Service Limit
--- | --- | --- | --- | ---
Block | Warpage of deck |  | 0.07 mm (0.003 in.) max. | 0.07 mm (0.003 in.)
Bore diameter A | X | 84.997−85.027 mm (3.3463−3.3475 in.) | 85.050 mm (3.3484 in.)
Y | 84.986−85.016 mm (3.3459−3.3471 in.) | 85.050 mm (3.3484 in.)
Bore diameter B | X | 84.987−85.017 mm (3.3459−3.3471 in.) | 85.050 mm (3.3484 in.)
Y | 84.976−85.006 mm (3.3455−3.3467 in.) | 85.050 mm (3.3484 in.)
Piston | Skirt O.D. at 14 mm (0.6 in.) from bottom of skirt | A | 84.950−84.980 mm (3.3445−3.3457 in.) | 84.920 mm (3.3433 in.)
B | 84.940−84.970 mm (3.3441−3.3453 in.) | 84.910 mm (3.3429 in.)
Clearance in cylinder |  | 0.006−0.065 mm (0.0002−0.0026 in.) | 0.065 mm (0.0026 in.)
Ring groove width | Top | 1.805−1.835 mm (0.0711−0.0722 in.) | 1.865 mm (0.073 in.)
Second | 2.06−2.08 mm (0.081−0.082 in.) | 2.100 mm (0.082 in.)
Oil | 3.02−3.04 mm (0.119−0.120 in.) | 3.070 mm (0.120 in.)
Piston ring | Ring-to-groove clearance | Top | 0.07−0.11 mm (0.003−0.004 in.) | 0.12 mm (0.005 in.)
Second | 0.04−0.08 mm (0.002−0.003 in.) | 0.10 mm (0.004 in.)
Oil | 0.02−0.06 mm (0.001−0.002 in.) | 0.08 mm (0.003 in.)
Ring end gap | Top | 0.25−0.35 mm (0.010−0.014 in.) | 0.57 mm (0.022 in.)
Second | 0.35−0.50 mm (0.014−0.020 in.) | 0.72 mm (0.028 in.)
Oil | 0.20−0.40 mm (0.008−0.016 in.) | 0.62 mm (0.024 in.)
Piston pin | O.D. |  | 29.995−30.000 mm (1.1809−1.1811 in.) | 29.985 mm (1.1805 in.)
Pin-to-piston clearance |  | 0.005−0.016 mm (0.0002−0.0006 in.) | 0.026 mm (0.0010 in.)
Connecting rod | Pin-to-rod clearance |  | 0.012−0.025 mm (0.0005−0.0010 in.) | 0.035 mm (0.0014 in.)
Small-end bore diameter |  | 30.012−30.020 mm (1.1816−1.1890 in.) | ———
Large-end bore diameter |  | 53.0 mm (2.09 in.) | ———
End play installed on crankshaft |  | 0.15−0.30 mm (0.006−0.012 in.) | 0.40 mm (0.016 in.)
Crankshaft | Main journal diameter | No. 1, 2, 3, 4 journals | 59.976−60.000 mm (2.3612−2.3622 in.) | ———
No. 5 journal | 59.972−59.996 mm (2.3611−2.3620 in.) | ———
Rod journal diameter |  | 49.976−50.000 mm (1.9676−1.9685 in.) | ———
Rod/main journal taper |  | 0.005 mm (0.00020 in.) max. | 0.006 mm (0.00023 in.)
Rod/main journal out-of-round |  | 0.005 mm (0.00020 in.) max. | 0.006 mm (0.00023 in.)
End play |  | 0.10−0.35 mm (0.004−0.014 in.) | 0.45 mm (0.018 in.)
Runout |  | 0.03 mm (0.0012 in.) max. | 0.03 mm (0.0012 in.)
Crankshaft bearing | Main bearing-to-journal oil clearance |  | 0.021−0.045 mm (0.0008−0.0018 in.) | 0.050 mm (0.0020 in.)
Rod bearing clearance |  | 0.021−0.051 mm (0.0008−0.0020 in.) | 0.060 mm (0.0024 in.)

Engine Lubrication

Item | Measurement | Qualification | Standard or New | Service Limit
--- | --- | --- | --- | ---
Engine oil | Capacity | Engine overhaul | 6.5 L (6.9 US qt, 5.7 Imp qt)
Oil change including filter | 5.9 L (6.2 US qt, 5.2 Imp qt)
Oil change without filter | 5.5 L (5.8 US qt, 4.8 Imp qt)
Oil pump | Inner-to-outer rotor clearance |  | 0.02−0.14 mm (0.0008−0.0055 in.) | 0.19 mm (0.0075 in.)
Pump housing-to-outer rotor clearance |  | 0.15−0.21 mm (0.006−0.008 in.) | 0.23 mm (0.009 in.)
Pump housing-to-rotor axial clearance |  | 0.020−0.055 mm (0.0008−0.0022 in.) | 0.10 mm (0.004 in.)
Relief valve | Oil pressure with oil temperature at 80 °C (176 °F) | At 820 rpm (min −1 ) | 110 kPa (1.1 kgf/cm 2 , 16 psi) min.
At 3,000 rpm (min −1 ) | 410 kPa (4.2 kgf/cm 2 , 59 psi) min.
Balancer shaft | Journal diameter | No. 1 journal, rear shaft | 23.938−23.950 mm (0.9424−0.9429 in.) | 23.92 mm (0.942 in.)
No. 2 journal, front and rear shafts | 23.938−23.950 mm (0.9424−0.9429 in.) | 23.92 mm (0.942 in.)
No. 3 journal, front and rear shafts | 32.949−32.961 mm (1.2972−1.2977 in.) | 32.93 mm (1.296 in.)
Journal taper |  | 0.005 mm (0.0002 in.) max. | ———
End play |  | 0.070−0.135 mm (0.0028−0.0053 in.) | 0.15 mm (0.006 in.)
Shaft-to-bearing clearance | No. 1 journal, rear shaft | 0.050−0.082 mm (0.0020−0.0032 in.) | 0.10 mm (0.004 in.)
No. 2 journal, front and rear shafts | 0.050−0.082 mm (0.0020−0.0032 in.) | 0.11 mm (0.004 in.)
No. 3 journal, front and rear shafts | 0.060−0.120 mm (0.0024−0.0047 in.) | 0.15 mm (0.006 in.)
Balancer shaft bearing | I.D. | No. 1 journal, rear shaft | 24.000−24.020 mm (0.9449−0.9457 in.) | 24.03 mm (0.946 in.)
No. 2 journal, front and rear shafts | 24.000−24.020 mm (0.9449−0.9457 in.) | 24.03 mm (0.946 in.)
No. 3 journal, front and rear shafts | 33.021−33.069 mm (1.3000−13.019 in.) | 33.09 mm (1.303 in.)

Cooling System

Item | Measurement | Qualification | Standard or New
--- | --- | --- | ---
Radiator | Coolant capacities (including engine, heater, hoses, and expansion tank) Use genuine Honda All Season Antifreeze/Coolant Type 2 | Engine overhaul | 8.0 L (2.11 US gal, 1.76 Imp gal)
Coolant change | 6.8 L (1.80 US gal, 1.50 Imp gal)
Reservoir | Coolant capacity |  | 0.9 L (0.24 US gal, 0.20 Imp gal)
Radiator cap | Opening pressure |  | 112−146 kPa (1.14−1.49 kgf/cm 2 , 16−21 psi)
Thermostat | Opening temperature | Begins to open | 76−80 °C (169−176 °F)
Fully open | 90 °C (194 °F)
Valve lift at fully open |  | 10.0 mm (0.39 in.) min.
Radiator fan switch (Low) | Thermoswitch ‘‘ON'' temperature |  | 91−95 °C (196−203 °F)
Thermoswitch ‘‘OFF'' temperature |  | Subtract 3−8 °C (5−15 °F) from actual ‘‘ON'' temperature
Radiator fan switch (High) | Thermoswitch ‘‘ON'' temperature |  | 98−102 °C (208−216 °F)
Thermoswitch ‘‘OFF'' temperature |  | Subtract 3−8 °C (5−15 °F) from actual ‘‘ON'' temperature

Fuel and Emissions

Item | Measurement | Qualification | Standard or New
--- | --- | --- | ---
Fuel tank | Capacity |  | 65 L (17.2 US gal, 14.3 Imp gal)
Engine idle | Idle speed without load | in neutral | 820±50 rpm (min −1 )

Clutch

Item | Measurement | Qualification | Standard or New | Service Limit
--- | --- | --- | --- | ---
Clutch pedal | Height from the floor | LHD type | 191 mm (7.52 in.) | ———
RHD type | 183 mm (7.20 in.) | ———
Stroke |  | 130−140 mm (5.12−5.51 in.) | ———
Play |  | 10−18 mm (0.39−0.71 in.) | ———
Disengagement height from the floor | LHD type | 90.5 mm (3.56 in.) min. | ———
RHD type | 86.5 mm (3.41 in.) | ———
Clutch disc | Rivet head depth |  | 1.0 mm (0.039 in.) min. | 0.2 mm (0.008 in.)
Thickness |  | 8.68−9.53 mm (0.342−0.375 in.) | 7.2 mm (0.28 in.)
Pressure plate | Warpage |  | 0.03 mm (0.001 in.) max. | 0.15 mm (0.006 in.)
Height of diaphragm spring fingers | Measured with special tool and feeler gauge | 0.6 mm (0.02 in.) max. | 0.8 mm (0.03 in.)