Tech:Engine/K-Series/TRD

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I'll let TRD do the talking!!!

http://www.vhtracing.com/TRD_K_ENGINE_MANUAL.pdf (Dead link)

http://www.rollaclub.com/hosted/TRD-K-Engine-Manual.pdf (Mirror, 25MB)

Link by Taz_Rx

Contents

Transcription

The aim of this transcription has been to faithfully reproduce a textual version of the historic TOSCO/TRD manual. Please DO NOT edit this except for correcting transcription errors. If you wish to comment or expand on sections of the TOSCO/TRD manual, please copy them to a new page and do so there.


People are encouraged to check any measurements or part numbers against the original manual in case of transcription errors.


Stage I

Without altering the displacement (1,166 cc), the pistons have been established to increase the compression ratio.

Cylinder Head Gasket, Piston & Piston Rings

(1) Main modifications

a. Cylinder head gasket.
Due to increase of compression ratio, the thickness upon assembling has been revised.
b. Piston
Without altering the displacement (75∅ 1,166cc), the compression ratio has been incrased.
c. Piston rings.
Two compression rings with thickness of 1 mm are utilized and the oil ring is of three-piece type with the thickness of 2.5mm.


(2) Required parts.

Description Qty.
Gasket,cylinder head 1
Ring set, piston 4
Piston w/pin 4

(3) Assembling standards.

Item Sports parts S. T. D
Piston clearance mm 0.06~0.08 0.03~0.05
Item Sports parts S. T. D
compression rings Oil ring Compression rings Oil ring
No. 1 No.2 No.1 No.2
Clearance between ring & ring groove (mm) 0.02~0.04 0.015~0.06 0.03~0.07 0.02~0.06 0.015~0.06
Gap clearance (mm) 0.15~0.35 0.20~0.90 0.15~0.35 0.20~0.90

Stage II

Besides the boring of the cylinder block and correction of the valve seats contacting surfaces, parts have been established which are capable for assembling almost without any modification.



1. PISTON & PISTON RINGS

(1) Main modifications.

a. Piston
The oversize is 3mm (78∅) with the displacement of 1,261 cc.
b. Piston rings
Two compression rings with the thickness of 1 mm are utilized.
The oil ring is of three-piece type with the thickness of 2.5 mm.



(2) Required parts.

Description Qty.
Gasket,cylinder head 1
Ring set, piston 4
Piston w/pin 4

(3) Assembling standards.

Item Sports parts S. T. D
Piston clearance mm 0.07~0.10 0.03~0.05
Item Sports parts S. T. D
compression rings Oil ring Compression rings Oil ring
No. 1 No.2 No.1 No.2
Clearance between ring & ring groove (mm) 0.02~0.04 0.015~0.06 0.03~0.07 0.02~0.06 0.015~0.06
Gap clearance (mm) 0.15~0.35 0.20~0.90 0.15~0.35 0.20~0.90

2. VALVE MECHANISM

(1) Main modifications.

a. Camshaft
The revise the valve timing, the cam profiles are revised.
b. Valves
To improve the intake and exhaust efficiency, the head diameters of the intake and exhaust valves have been enlarged.
c. Valve springs.
To prevent surging, revised from single to dual springs and the installed load is revised.
d. Valve spring retainer & spring seat.
Due to the revision of the valve springs from single to dual, the retainer and seat are newly established.

(2) Required parts.

No. Part No. Description Qty. Remarks
1 13511-KE003 Camshaft Either one Overlap 70°
13511-KE051 Camshaft Overlap 66°
2 13711-KE051 Valve, intake 4 Head dia. 37∅
3 13715-KE051 Valve, exhaust 4 Head dia. 30∅
4 90501-42409 Spring, compression (outer) 8 "O"
5 90502-KE501 Spring, compression (inner) 8
6 13734-KE051 Seat, valve spring 8
7 13741-KE051 Retainer, valve spring 8
8 90913-03005 Lock, valve spring retainer 16 "O"

(3) Assembling procedures & assembling standards.

Replace with the above parts.

3. INTAKE & EXHAUST SYSTEMS

(1) Main modifications

a. Intake manifold.
Matched with the carburetor throttle bore, enlarged the ports to reduce the intake resistance.
b. Exhaust manifold.
Revised the shape to improve the exhaust efficiency.


(2) Required parts.

No. Part No. Description Qty. Remarks
1 17104-KP751 Manifold sub-assy. exhaust 1
2 17111-KE051 Manifold sub-assy. intake 1
3 21911-TE001 Gasket, carburetor 8 40∅
4 21912-TE001 Insulator, carburetor heat 4 40∅


(3) Assembling procedures.

Replace with the above parts.


4. FUEL SYSTEM & ACCELERATOR LINKAGE

(1) Main modifications.

a. Carburetor.
Revised the throttle bore to match the specification for high speed driving.
b. Accelerator linkage.
Due to the revision of the carburetor, the shape of the linkage is revised.


(2) Required parts.

No. Part No. Description Qty. Remarks
1 21001-SP001 Carburetor set 1 Dellorto DHLA40 x 2
2 78022-KE002 Linkage set, accelerator 1


(3) Assembling procedures.

Replace with the above parts.

TRD Fig1.png

STAGE III

1. CYLINDER HEAD

(1) Main modifications.

Enlarge the intake and exhaust ports to improve the intake and exhaust efficiency. Also, due to the revision of the valves and valve springs, machined the valve spring seats portions and inserted the valve seat rings and valve guides.

Item Detail Size & etc.
Intake valve Replaced Head dia. 38∅ stem dia. 6.6∅
Exhaust valve " Head dia. 33∅ stem dia. 6.6∅
Valve guide bushing (IN.) " Bore 6.6∅
Valve guide bushing (EX.) " Bore 6.6∅
Valve seat ring (IN.) "
Valve seat ring (EX.) "
Valve spring seat portion Machined Recess machining
Port shape " Grinding for enlarging
Combustion chamber shape " Capacity revised


Caution
At the same time with the modification of the cylinder head, perform the surface grinding of the cylinder block top surface.
(Refer to cylinder block paragraph.)

(2) Required Parts.

No. Part No. Description Qty. Remarks
1 Head assy, cylinder
2 11115-KE003 Gasket, cylinder head 1
3 11131-KE002 Seat, intake valve 4
4 11135-KE002 Seat, exhaust valve 4
5 11121-KE001 Bushing, valve guide (IN) 4
6 11125-KE001 Bushing, valve guide (EX) 4
7 90520-12049 Ring, shaft snap 8 "O"
8 90116-KE001 Bolt, stud 2
9 90116-KE002 Bolt, stud 6

TRD Fig2.png

(3) Machining procedures & assembly standard.

a. Valve guide bushing replacement.
Due tot he revision of the valve stem diameter, the valve guide is revised with a smaller bore (6.6∅) item.
Valve guide bushing x cylinder head
Fitting allowance - 0.018 ~ 0.035 mm (20°C)
Caution
The replacement of the valve guide bushing must accord to the repair manual procedures of the conventional engine. Also, after replacement, inspect the bushing bore and correct with a reamer if found defective.
b. Valves seat ring replacement.
Due to the revision of the valve head diameter, replace the intake and exhaust seat rings.
Head the cylinder head to about 130°C, cool the valve seat ring with dry ice to shrink and fit.
The intake valve seat ring must protrude into the combustion chamber 1 mm more than the exhaust. (Refer to Fig. 3-a & 3-b.)
Cylinder head x valve seat ring
Fitting allowance - 0.07 ± 0.01 mm.



Caution
Sufficent care must be taken so that there is no clearance between the ring seat and the cylinder block and also for inclination of the ring.



TRD Fig3a.png TRD Fig3b.png


Contact surface angle 45°
Contact surface correction angles 15° 45° 65°
Contact width Intake mm 1.2 +0.2 -0
Exhaust mm 1.2 +0.2 -0
c. Valve spring seat portion machining.
Machine the valve spring portion 1.3 mm for recess from the standard surface (Refer to Fig. 3-a & 3-b.)
d. Port grinding.
Intake.
Perform the grinding by maintaining the standard shape.

TRD Fig4.png



Exhaust.
Grind the oblique lines of the Fig. 3-b.



e. Combustion chamber machining & cylinder head surface grinding.
When revising the combustion chamber shape, surface grind the cylinder head surface to obtain the compression ratio of 11.3 ~ 11.5 at the same time.



TRD Fig5.png



Combustion chamber capacity
As a unit - 22 ~ 23 cc
When assembled - 31 cc



f. Water jacket machining.
Depending on the grinding volume of the cylinder head, warpage may be produced from heat and installation of the cylinder head.
To countermeasure this, perform the argon welding on the water jacked before grinding the cylinder head surface (Refer to Fig. 5.)


Caution
After machining the b, c and e, perform the water test for 5 ~ 10 minutes at 2 kg/cm²


g. Replacement of rocker supporting securing bolts.
To prevent damaging of the cylinder head threads, replace the rocker support securing bolts (90910-01005 x 6, 90116-08127 x 2) to (7), (8) stud bolts.


2. CYLINDER BLOCK

(1) Main modifications.

Increased the cylinder bore from 75∅ to 79∅ (displacement from 1,166 -> 1,293 cc), grind the cylinder block top surface with a surface grinder.


(2) Required part.

No. Part No. Description Qty.
1 11495-SP001 Plate plug (fuel pump hole) 1



(3) Machining procedures & assembling standards.

a. Surface grinding.
Due to the revision of the dimension above the pin of the piston, surface grind the cylinder block top surface.

TRD Fig6.png


Cylinder block top surface
Warpage allowance - 0.02 mm


b. Boring.
To enlarge the cylinder bore from 75∅ to 79∅ perform the boring and honing.
The cylinder bore must be the minimum actual value of thrust direction in relation between 15 mm to 110 mm from the block top surface.


Caution
  1. The piston diameter must be the maximum actual value at 7mm above the piston skirt in thrust direction at normal temperature (20°C).
  2. After machining, perform the water test for 5 ~ 10 minutes at 2kg/cm².


c. Chamfering of the cylinder skirt.
Chamfer the cylinder skirt with an air grinder or file (2 ~ 3°)


d. Revise the bolts securing the oil filter and alternator bracket and thread to M10, P-1.25 to improve strength.

3. PISTON & PISTON RINGS

(1) Main modifications.

a. Piston
Revised the shape to provide a flat head.
b. Piston rings.
Will utilize a compression ring with the thickness of 1 mm.
The oil ring is of three piece type with the thickness of 2.5 mm.
c. Piston pin.
Revised the outer diameter of the piston pin from 18∅ to 20∅ to improve the strength.

(2) Required parts.

No. Part No. Description Qty.
1 13011-KE004 Ring set, piston 4
2 13011-KE006 Piston w/pin 4

TRD Fig7.png




(3) Assembling procedures & assembling standards.

a. Fitting of piston with the cylinder block.
The minimum actual value of the cylinder bore in relation to the thrust direction at between 15 ~ 110 mm from the cylinder top surface and the difference (clearance) with the maximum actual value above 7 mm from the end of the piston skirt in thrust direction must accord to the List 8 upon assembly. (Refer to cylinder block paragraph.)
List 8
Item Sports parts
Piston standard diameter mm
78.96 +0.02
-0
piston clearance mm 0.07~0.10
b. Weight difference of pistons.
The weight difference of each per one unit (including piston pin) must be within 2 grams.
c. Piston pin.
Heat the piston to 80°C in oil and further chamfer the end surface of the pin with an oil stone to smoothen then insert carefully without scratching the corresponding part.


List 9
Item Sports parts
Piston pin bore mm
20 +0.012
-0
Piston pin outer diameter
20 +0.017
+0.005
Caution
It is satisfactory when the pin can be pushed into the piston with the thumb at 80°C.


d. Piston rings.
List 10
Item Sports parts S. T. D
Piston clearance mm 0.06~0.08 0.03~0.05
Item Sports parts S. T. D
Compression

ring

Oil ring Compression rings Oil ring
No. 1 No.2
Clearance between ring & ring groove (mm) 0.02~0.04 0.015~0.06 0.03~0.07 0.02~0.06 0.015~0.06
Gap clearance (mm) 0.15~0.35 0.20~0.90 0.15~0.35 0.15~0.35 0.20~0.90
Caution
To prevent vertical scratching of the cylinder bore with the compression ring ends, assemble after shamfering smoothly with an (ed: missing word, file?)

4. CONNECTING ROD, CRANKSHAFT & FLYWHEEL

====(1) Main modifications.

a. Connecting rod.
Revise the material to improve durability.
Also, the small end is of less bushing type.
b. Crankshaft.
Oil clearance is provided and dynamic balancing has been performed.
c. Flywheel.
Lightened the weight and dynamic balancing has been performed.


(2) Required parts.

No. Part No. Description Qty. Remark
1 13201-KE001 Rod sub-assy, connecting 4
2 90105-10030 Bolt, flywheel set 6 "O"

(3) Installing procedures & assembling standards.

a. Connecting rod.
For fitting the piston pin, apply oil onto the piston pin and it is excellent when it can be easily inserted at normal temperature.
List 11
Item Sports parts S. T. D
Connecting rod bolt tightening torque kg.cm 500 400~520
Clearance between piston pin & connecting rod mm 0.09~0.014 0.004~0.008
Bend limit (per 100 mm) mm 0.04 0.05
Twist limit (per 100 mm) mm 0.04 0.15
b. Crankshaft.
Adjust the clearances of the journals and crankpins.
List 12
Item Racing specification S. T. D
Journal oil clearance mm 0.05~0.07 0.016~0.040
Crankpin oil clearance mm 0.04~0.06 0.024~0.048
Journal thrust clearance mm 0.04~0.15 0.01~0.222
Bearing cap bolt tightening torque kg.cm 600 540-660
Roundness limit mm 0.008 0.01
Bend limit mm 0.02 0.03
c. Flywheel.
Discontinued the standard flywheel securing bolts (90105-01005) and lock plates and will utilize (2) (90105-10030).
Crankshaft x flywheel
Tightening torque - 800kg.cm
Caution
It is desirable to perform the dynamic balancing with the flywheel and crankshaft as a unit and the unbalancing volume must be within 2g.cm.

5. VALVE MECHANISM

(1) Main modifications.

a. Camshaft.
The valve timing and cam profiles are revised.

TRD Fig8.png


List 13
Part No. Valve timing Cam lift

mm

Valve clearance

mm

Cam top center
A B C D E F
13511-KE001 53 91 87 55 7.5 IN:0.35

EX:0.38

106 109
13511-KE003 35 70 70 35 7.4 IN:0.35

EX:0.35

110 110
13511-KE005 54 86 94 46 7.2 IN:0.3

EX:0.4

106 114
13511-KE051 36 64 70 30 6.8 IN:0.3

EX:0.3

104 110


b. Valves.
To improve the intake and exhaust efficiency and to lighten the weight, revised the shape and dimension.
List 14
Item Sports parts S. T. D
IN EX IN EX
Head diameter mm 38 33 36 29
Stem diameter mm 6.6 6.6 8 8
Overall length mm 96.8 95.8 100.1 100.1
Head thickness limit mm 0.5 0.5 0.8 0.9
c. Valve springs.
For high performance of the engine, revised the valve springs from single to dual type.
List 15
Item Outer Inner
Free length mm 41.8 37.6
Installed length mm 38 32
Installed load kg 16 7
Effective windings 3.3 5.8
Coil wire diameter mm 4.2 2.6
Average coil diameter mm 28 18.4
d. Valve spring retainer.
Revised the shape for dual spring type.
e. Valve stem pad.
To maintain contact surface with the rocker arm the pad will be utilized.
f. Rocker support.
Due to the revision of the valve length provided an addition machining on the standard part.
g. Rocker arm spacer
The spring between the rocker arm is replaced with the spacer to reduce the resistance.
h. Push-rod.
To lighten, the material is revised.
i. Valve lifter.
Provided an additional machining on the standard part for desirable lightening.
j. Timing gear (for camshaft).
Provided with 7 dowel pin holes for easy selection of the camshaft.


The racing specification sports parts described here have been established by sufficiently maintaining the basic features of the Toyota 3K model engine and right-hand-drive car.

Select the tuning detail in accordance to the racing regulations. When the tuning is performed the driving on public roads must not be performed.

Reference
  1. The parts indicated in the remark column of this manual with the "O" marks indicate the genuine parts.
  2. Always adhere to precautions upon handling and on assembling standards.
  3. Please utilize genuine parts when the parts are not specially specified.
  4. We reserve the right to modify the sports parts without notice.


(2) Required parts.

No. Part No. Description Qty. Remark
1 13708-KE003 Rod sub-assy., valve push 8
2 13711-KE003 Valve, intake 4
3 13715-KE003 Valve, exhaust 4
4 90501-KE001 Spring, compression (outer) 8
5 90502-KE001 Spring, compression (inner) 8
6 90201-24215 Seat, valve spring (outer) 8 "O"
7 13734-11010 Seat, valve spring (inner) 8 "O"
8 13741-KE002 Retainer, valve spring 8
9 90913-KE001 Lock, valve spring retainer 16
10 90072-72661

90072-72681

Pad, retainer 8 "O"
11 26908-KE005 Spacer, rocker arm No.2 2
12 26908-KE006 Spacer, rocker arm No.3 1
13 13951-KE001 Support, valve rocker 4
14 13511-KE001 Camshaft either one
13511-KE003 Camshaft
13511-KE005 Camshaft
13511-KE051 Camshaft
15 13523-KE002 Gear, camshaft timing 1

TRD Fig9.png

Caution
On the camshafts 13511-KE001 and 13511-KE005, as the cam for driving the fuel pump is not provided, electric fuel pump is adapted.
b. Valves
List 16
Item Sports parts
Face contact width mm
1.2 +0.2
-0
Oil clearance between valve guide (specified) mm 0.05
(limit) mm 0.08
Valve stem end correction limit mm 0.5
Caution
Be careful with the face contact surface and contact width and the dressing of the valve and valve seat must be performed sufficiently.
c. Rocker support.
Cut the bottom surface of the standard part (13951-22010).

TRD Fig11.png

Parallelism limit of the rocker shaft center and rocker support bottom surface - 0.03 mm.
d. Valve lifter.
To lighten, reduceds(sic) the thickness of the standard part.

TRD Fig12.png


6. LUBRICATION SYSTEM

(1) Main modifications

a. Oil pump
Partially revised the standard part.
b. Oil pan.
Due to up-right positioning of the engine, revised the shape.
c. Oil strainer.
Due to the revision of the oil pan, revised the shape.
d. Oil cooling system.
Newly established the camshaft driven oil cooler pump.


No. Part No. Description Qty. Remark
1 157710-26010 Cooler assembly, oil 1
2 11321-KE001 Cover sub-assy., timing chain 1
3 Drive set, oil pump 1
4 15115-KE001 Cover, oil pump No.1 1
5 04151-KE001 Rotor set, oil pump 1
6 15115-KE002 Cover, oil pump No.2 1
7 90301-44049 Ring, "O" 1 "O"
8 91611-60650 Bolt (for oil pump cover securing) 4 "O"
9 90404-KE001 Union 2
10 Clamp 6
11 90405-KE002 Union 4
12 90401-12075 Union 4 "O"
13 90430-12015 Washer 8 "O"
14 Hose, oil cooler
15 15100-24010 Pump assembly, oil 1 "O"
16 15104-KE002 Strainer sub-assy., oil 1
17 12101-KE002 Pan sub-assy,. oil 1 For 3K-B
12101-KE003 Pan sub-assy,. oil 1 For 3K-H


TRD Fig13.png


====(3) Machining procedures & assembling standards.

a. Oil pump.
Shim with the thickness of 2 ~ 4 mm is inserted between the relief valve spring and relief valve to maintain the oil pressure at 6kg/cm² (standard 4kg/cm²).
Also, with the engine prior to April 1974, please always utilize the 15100-24100.
b. Oil filter.
For 3K model, utilize (15601-33020) or (15600-25100) for T and 2T models. When utilizing 15600-25010 modification is required on the oil filter bracket (15609-254010).
(Refer to Fig. 14)

TRD Fig14.png


Caution
If there is a by-pass inside the filter, it is desirable to utilize the 15600-25100.
As the front timing cover rear oil seal retainer shape differs from the 3K-H model engine (after April 1974) and 3K-B model, sufficient care should be taken upon installation and modification.

7. INTAKE & EXHAUST SYSTEMS

(1) Main modifications.

a. Intake manifold.
It is of separate type from the exhaust manifold and it is of alloy metal.
The ports are also enlarged to match the carburetor throttle bore to reduce the intake resistance.
b. Exhaust manifold.
To improve the exhaust efficiency, it is of 4-2-1 type and for 4-speed (for K-40) and for 5-speed (for T-50), these are made available.
c. Manifold stay.
Due to the separation of the intake and exhaust manifolds, the alloy metal stays are prepared for installation of the manifolds.

(2) Required parts.

No. Part No. Description Qty. Remark
1 17118-KE001 Stay, manifold 1
2 17111-KE001 Manifold intake 2
3 17104-KP702 Manifold sub-assy., exhaust Either one For 4-speed
17104-KP703 Manifold sub-assy,. exhaust For 5-speed
4 17173-KE001 Gasket, exhaust manifold No.1 2
5 17173-KE002 Gasket, exhaust manifold No.2 1
6 17177-KE001 Gasket, intake manifold 2
7 17172-KE001 Gasket, manifold to cylinder head 2
8 92132-40820 Bolt, stud 6 "O"
9 92122-KE001 Bolt, stud 4
10 92122-41020 Bolt, stud 5 "O"
11 92132-41035 Bolt, stud 2 "O"

TRD Fig15.png


(3) Machining procedures & assembling standards.

a. Intake manifold.
Grind the ports to match the size of the gaskets
b. Exhaust manifold.
Grind the ports similar to the intake manifold.
c. Manifold stay.
Grind the contact surfaces of the cylinder head and manifolds so that these can be connected with gradual curved surfaces without any irregularity.

8. FUEL SYSTEM

(1) Main modifications.

a. Carburetor.
Revise the throttle bore to meet the specification for high speed driving.
List 17
Item Specification
Throttle valve diameter 45∅
Large venturi diameter 38∅~40∅
Small venturi 8011-1
Main jet size 160#~200#
Air jet size 180#~220#
Emulsion tube ET7772-2
Idle jet side 50#
Pump jet size 33#~
Needle valve size 170#
Fuel level height 8.0mm
Air horn length 50mm
b. Fuel pump & filter.
Due to the revision of the camshaft and carburetor, will utilize the electric pump.
List 18
Item Sports parts S. T. D
Type Electro-magnet Diaphragm
Discharge volume 1500cc/min 900cc/min
Discharge pressure 0.36kg/cm² 0.2~0.3kg/cm²
Rated voltage 12V
Rated current 2.3A

(2) Required parts.

No. Part No. Description Qty. Remark
1 21001-SP002 Carburetor set 1 Dellorto

DHLA45 x 2

2 23100-SP001 Pump assembly, fuel 1
3 23300-SP001 Filter assembly, fuel 1
4 23109-50010 Mounting sub-assy., fuel pump 2

TRD Fig16.png

(3) Assembling procedures & assembling standards.

Replace with the above parts.

Caution
Upon installation of the fuel pump, the rubber mounting which is supplementary to the assembly, must always be utilized.

9. ACCELERATOR LINKAGE

(1) Main modifications.

Due to the revision of the carburetor, exclusive linkage has been established.

(2) Required part.

No. Part No. Description Qty.
1 78022-KE002 Linkage set, accelerator 1

TRD Fig17.png

10. IGNITION SYSTEM COMPONENTS & COOLING SYSTEM.

(1) Main modifications.

a. Distributor.
The advancing device is revised to stationary type and also improved the durability of the spiral gear.
List 19
Item Sports parts S. T. D
Advancing device Centrifugal type None Yes
Vacuum type None Yes
Point contacting pressure g 510-690
Point gap mm 0.4~0.5
Condenser capacity uF 0.20~0.24
Weight kg 0.7 1.1


b. Alternator pulley.
To prevent the over-running of the alternator during high speed, revised the pulley diameter.
c. Cooling system.
Replaced the radiator with a larger radiation.

(2) Required parts.

No. Part No. Description Qty.
1 Distributor assembly 1
2 Pulley, alternator 1

(3) Assembling procedures & assembling standards.

Ignition timing
B.T.D.C - 38 ~ 40&°/4,000rpm

11. ENGINE MOUNTS, TRANSMISSION HOUSING & SUPPORT

(1) Main modifications.

Due to the revision of the engine from slanting to up-right type, newly established the engine mounts, transmission housing (for 5-speed) and transmission support (for 4-speed).

(2) Required parts.

No. Part No. Description Qty. Remark
1 12301-KE001 Bracket sub-assy., engine mount Front RH 1
2 12302-KE001 Bracket sub-assy., engine mount Front LH 1
3 31111-KP701 Housing assembly 1 For 5-speed
4 57209-KE001 Member sub-assy., engine rear support 1 For 4-speed

(3) Assembling procedures.

Replace with the above parts.


Service Standards

Cylinder Head

Item S. T. D Racing specification
Bottom surface warpage limit mm 0.10 0.05
Valve seat Contact surface angle 45° 45°
Contact surface width mm Intake 1.4
1.2 +0.2
-0
Exhaust 1.5
1.2 +0
-0

Cylinder Block

Item S. T. D Racing specification
Top surface warpage limit mm 0.05 0.05
Valve lifter hole boremm 20.000~20.021
Cylinder Bore mm 75.00~75.05 79.03~79.08
Wear limitmm 0.2 0.06
Taper, roundness limitmm 0.02
Cylinder bore differencemm 0.05
Liner Fitting allowancemm 0.055~0.15
Fitting loadkg 2000~3000

Piston, Piston Pin, Piston Rings

Item S. T. D Racing specification
Piston Diametermm 74.97~75.02 78.96~78.98
Clearance between cylindermm 0.03~0.05 0.07~0.10
Piston pin fitting temperature 70~80 80
Piston ring gap Compression ring No.1 No.2 mm 0.15~0.35
Oil ringmm 0.015~0.06
Clearance between ring & groove Compression ring mm 0.015~0.06 0.03~0.05
Oil ring mm 0.015~0.06
Piston pin outer diametermm 17.999~18.011 20.005~20.017

Connecting Rod, Bearing

Item S. T. D Racing specification
Bend limit (per 100mm)mm 0.05 0.05
Twist limit (per 100mm)mm 0.15 0.05
Large end thrust clearance Limit mm 0.3 0.3
Specified mm 0.110~0.214
Clearance between Limit mm 0.05 0.05
Specified mm 0.004~0.008 0.009~0.014
Bearing oil clearance pin & bore Limit mm 0.10
Specifiedmm 0.024~0.048 0.04~0.06

Crankshaft

Item S. T. D Racing specification
Bend limitmm 0.03 0.02
Thrust clearance Limitmm 0.3 0.3
Specifiedmm 0.04~0.222 0.06~0.15
Taper, roundness limitmm Less than 0.01
Journal diametermm 49.976~50.00
Journal oil clearancemm 0.016~0.040 0.05~0.07
Crankpin diametermm 41.976~42.000
Crankpin oil clearancemm 0.024~0.048 0.04~0.06
Thrust washer widthmm 2.43~2.48


Timing Chain, Sprocket

Item S. T. D Racing specification
Deflection limit (load 10kg)mm 13.5
Vibration damper thickness limitmm 7
Tension plunger head thickness limitmm 12
Camshaft timing sprocket wear limitmm 113.8

(Measure diameter w/chain installed)

Crankshaft timing sprocket wear limit 59.4

(Measure diameter w/chain installed)

Chain deflection limitmm 272.7

(load 5kg)


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