NOTE
Do not move the connecting rod and crankshaft during clearance measurement.
Remove the connecting rod big end again, measure each clearance between the bearing insert and crankpin [A] using plastigage (press gauge) [B].
NOTICE
After measurement, replace the connecting rod bolts and nuts.
Connecting Rod Big End Bearing Insert/Crankpin Clearance
Standard: 0.030 0.060 mm
(0.0012 0.0024 in.)
Service Limit: 0.10 mm (0.0039 in.)
If the clearance is within the standard, no bearing replacement is required.
If the clearance is between 0.061 mm (0.0024 in.) and the service limit (0.10 mm, 0.0039 in.), replace the bearing inserts [A] with inserts painted blue [B]. Check insert/ crankpin clearance with the plastigage. The clearance may exceed the standard slightly, but it must not be less than the minimum in order to avoid bearing seizure.
If the clearance exceeds the service limit, measure the diameter of the crankpins.
Crankpin Diameter
Standard: 34.484 34.500 mm
(1.3576 1.3583 in.)
Service Limit: 34.47 mm (1.3571 in.)
Crankpin Diameter Marks
None 34.484 34.492 mm (1.3576
1.3580 in.)
34.493
34.500 mm (1.3580
1.3583 in.)
: Crankpin Diameter Marks (“” or
No Mark)
NOTE
The mark already on the big end should almost coincide with the measurement.
Connecting Rod Big End Inside Diameter Marks
None 37.500 37.508 mm
(1.4764 1.4767 in.)
37.509
37.516 mm (1.4767
1.4770 in.)
Big End Cap [A] Connecting Rod [B] Weight Mark, Alphabet [C] Diameter Mark [D] (“” or No Mark)
Size Color [B]
DFI Power Source
ECU Fuse Removal
Refer to the 30 A Main/15 A ECU Fuse Removal in the
Electrical System chapter.
ECU Fuse Installation
If a fuse fails during operation, inspect the DFI system to
determine the cause, and then replace it with a new fuse
of proper amperage.
Refer to the Fuse Installation in ...
Subthrottle Valve Actuator Inspection
NOTE
Be sure the battery is fully charged.
Remove the air cleaner housing (see Air Cleaner Housing
Removal in the Fuel System (DFI) chapter).
Turn the ignition switch to ON.
Check to see that all the subthrottle valves [A] open and
close smoothly.
Turn the ignition switch to OFF.
I ...
Tie-Rod and Rocker Arm Bearing Removal
Remove:
Tie-Rod (see Tie-Rod Removal)
Rocker Arms (see Rocker Arm Removal)
Swingarm (see Swingarm Removal)
Sleeves [A]
Oil Seals [B]
Remove the needle bearings [C], using the bearing remover
head and bearing remover shaft.
Special Tools - Bearing Remover Head,
15 ×
17: ...