Standards and Service Limits (cont'd) — Fuel and Emission, Clutch, Manual Transmission
3-4spec tableUnverifiedIdle speed split by engine type and market: SOHC KY 780, SOHC Ex.KY 750, DOHC KQ 750, DOHC Ex.KQ 800 rpm. Idle CO differs With vs Without Catalytic Converter.
6. Fuel and Emission
Fuel pump
MeasurementDelivery pressure
Standard (New)250 kPa (2.55 kg/cm², 36 psi)
Fuel pump
MeasurementDisplacement
Standard (New)236 cc /minutes in 10 seconds min.
Fuel pump
MeasurementRelief valve opening pressure
Standard (New)441—588 kPa (4.5—6.0 kg/cm², 64—85 psi)
Pressure regulator
MeasurementPressure
Standard (New)230—270 kPa (2.35—2.75 kg/cm², 33—39 psi)
Fuel Tank
MeasurementCapacity
Standard (New)45 ℓ (11.9 U.S. gal., 9.9 Imp. U.S. gal.)
Fast idle
MeasurementFast idle
Standard (New)1,000—2,000 min⁻¹ (rpm)
Idle speed
Measurementwith headlights and cooling fan off SOHC KY
Standard (New)780 ± 50 min⁻¹ (rpm)
Idle speed
Measurementwith headlights and cooling fan off SOHC Ex. KY
Standard (New)750 ± 50 min⁻¹ (rpm)
Idle speed
Measurementwith headlights and cooling fan off DOHC KQ
Standard (New)750 ± 50 min⁻¹ (rpm)
Idle speed
Measurementwith headlights and cooling fan off DOHC Ex. KQ
Standard (New)800 ± 50 min⁻¹ (rpm)
Idle CO
MeasurementWith Catalytic Converter
Standard (New)0.1% Max.
Idle CO
MeasurementWithout Catalytic Converter
Standard (New)1.0 ± 1.0%
7. Clutch
Clutch pedal
MeasurementPedal height
Standard (New)213 (8.39) to floor
Service Limit—
Clutch pedal
MeasurementStroke
Standard (New)140—150 (5.5—5.9)
Service Limit—
Clutch pedal
MeasurementPedal play
Standard (New)15—20 (0.59—0.79)
Service Limit—
Clutch pedal
MeasurementDisengagement height
Standard (New)70 (2.76) min. to floor
Service Limit—
Flywheel
MeasurementClutch surface runout
Standard (New)0.05 (0.002) max.
Service Limit0.15 (0.006)
Clutch disc
MeasurementRivet head depth
Standard (New)1.3 (0.05) min.
Service Limit0.2 (0.008)
Clutch disc
MeasurementSurface runout
Standard (New)0.8 (0.03) max.
Service Limit1.0 (0.04)
Clutch disc
MeasurementThickness
Standard (New)8.1—8.8 (0.32—0.35)
Service Limit5.7 (0.224)
Clutch release bearing holder
MeasurementI.D.
Standard (New)31.00—31.15 (1.220—1.226)
Service Limit31.2 (1.228)
Clutch release bearing holder
MeasurementHolder-to-guide sleeve clearance
Standard (New)0.05—0.239 (0.002—0.009)
Service Limit0.28 (0.011)
Clutch cover
MeasurementUneveness of diaphragm spring
Standard (New)0.8 (0.03) max.
Service Limit1.0 (0.04)
Clutch release lever
MeasurementLever play
Standard (New)4.0—5.0 (0.16—0.20)
Service Limit—
8. Manual Transmission
Transmission oil
MeasurementCapacity ℓ (US.qt., Imp.qt.)
Standard (New)1.8 (1.9, 1.6) at oil change; 2.4 (2.1, 2.5) at assembly
Service Limit
Mainshaft
MeasurementEnd play
Standard (New)0.13—0.20 (0.005—0.008)
Service LimitAdjustable
Mainshaft
MeasurementDiameter of needle bearing contact area
Standard (New)25.977—25.990 (1.0227—1.0232)
Service Limit25.92 (1.020)
Mainshaft
MeasurementDiameter of third gear contact area
Standard (New)33.984—34.000 (1.3380—1.3386)
Service Limit33.93 (1.336)
Mainshaft
MeasurementDiameter of 4th, 5th gear contact area
Standard (New)26.980—26.993 (1.0622—1.0627)
Service Limit26.93 (1.060)
Mainshaft
MeasurementDiameter of ball bearing contact area
Standard (New)21.987—22.000 (0.8656—0.8661)
Service Limit21.93 (0.863)
Mainshaft
MeasurementRunout
Standard (New)0.02 (0.0008) max.
Service Limit0.05 (0.002)
Mainshaft third and fourth gears
MeasurementI.D.
Standard (New)39.009—39.025 (1.5358—1.5364)
Service Limit39.07 (1.538)
Mainshaft third and fourth gears
MeasurementEnd play 3rd
Standard (New)0.06—0.21 (0.0012—0.008)
Service Limit0.33 (0.013)
Mainshaft third and fourth gears
MeasurementEnd play 4th
Standard (New)0.06—0.19 (0.0024—0.0075)
Service Limit0.31 (0.012)
Mainshaft third and fourth gears
MeasurementThickness 3rd
Standard (New)30.22—30.27 (1.1898—1.1917)
Service Limit30.15 (1.187)
Mainshaft third and fourth gears
MeasurementThickness 4th
Standard (New)30.12—30.17 (1.1858—1.1878)
Service Limit30.05 (1.183)
Mainshaft fifth gear
MeasurementI.D.
Standard (New)37.009—37.025 (1.4570—1.4577)
Service Limit39.07 (1.538)
Mainshaft fifth gear
MeasurementEnd play
Standard (New)0.06—0.19 (0.0024—0.0075)
Service Limit0.31 (0.012)
Mainshaft fifth gear
MeasurementThickness
Standard (New)28.42—28.47 (1.1189—1.1209)
Service Limit28.35 (1.116)
Countershaft
MeasurementEnd play
Standard (New)0.17—0.38 (0.0067—0.0150)
Service Limit0.53 (0.021)
Countershaft
MeasurementDiameter of needle bearing contact area
Standard (New)30.000—30.015 (1.1811—1.817)
Service Limit29.95 (1.179)
Countershaft
MeasurementDiameter of ball bearing contact are
Standard (New)24.980—24.993 (0.9835—0.9840)
Service Limit24.93 (0.981)
Countershaft
MeasurementDiameter of low gear contact area
Standard (New)35.984—36.000 (1.4167—1.4173)
Service Limit35.93 (1.415)
Countershaft
MeasurementRunout
Standard (New)0.02 (0.0008) max.
Service Limit0.05 (0.002)
Countershaft low gear
MeasurementI.D.
Standard (New)41.009—44.025 (1.6145—1.6152)
Service Limit41.07 (1.617)
Countershaft low gear
MeasurementEnd play
Standard (New)0.03—0.10 (0.0012—0.0039)
Service Limit0.22 (0.009)
Countershaft low gear
MeasurementThickness
Standard (New)29.41—29.44 (1.1579—1.1591)
Service Limit29.36 (1.156)
Countershaft second gear
MeasurementI.D.
Standard (New)44.009—44.025 (1.7326—1.7333)
Service Limit44.07 (1.735)
Countershaft second gear
MeasurementEnd play
Standard (New)0.03—0.11 (0.0012—0.0043)
Service Limit0.23 (0.009)
Countershaft second gear
MeasurementThickness
Standard (New)29.92—29.97 (1.1780—1.1799)
Service Limit29.85 (1.175)