NOTE
Split the crankcase again, measure each clearance between the bearing insert and journal [B] using plastigage (press gauge).
Crankshaft Main Bearing Insert/Journal Clearance
Standard: 0.010 0.034 mm
(0.0004 0.0013 in.)
Service Limit: 0.06 mm (0.0024 in.)
If the clearance is within the standard, no bearing replacement is required.
If the clearance is between 0.035 mm (0.0014 in.) and the service limit (0.06 mm, 0.0024 in.), replace the bearing inserts [A] with inserts painted blue [B]. Check insert/journal clearance with the plastigage. The clearancemay 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 crankshaft main journal.
Crankshaft Main Journal Diameter
Standard: 34.984 35.000 mm
(1.3773 1.3780 in.)
Service Limit: 34.96 mm (1.3764 in.)
If any journal has worn past the service limit, replace the crankshaft with a new one.
If themeasured journal diameters [C] are not less than the service limit, but do not coincide with the original diameter markings [D] on the crankshaft, make new marks on it.
Crankshaft Main Journal Diameter Marks
None 34.984 34.992 mm (1.3773
1.3776 in.)
1 34.993 35.000 mm (1.3777
1.3780 in.)
: Crankshaft Main Journal
Diameter Marks (“1” or No
Mark)
[A]: Crankcase Main Bearing Inside Diameter Marks, “” or no mark.
NOTE
The mark already on the upper crankcase half should almost coincide with the measurement.
Crankcase Main Bearing Inside Diameter Marks
38.000 38.008 mm (1.4961
1.4964 in.)
None 38.009 38.016 mm (1.4964
1.4967 in.)
Size Color [B]
*: The bearing inserts for Nos. 2 and 4 journals have an oil groove, respectively.
Air Cleaner Element Replacement
NOTE
In dusty areas, the element should be replaced more
frequently than the recommended interval.
WARNINGIf dirt or dust is allowed to pass through
into the
throttle body assy, the throttle may become stuck,
possibly causing accident. Replace the air cleaner
element according ...
Front Master Cylinder Installation
Apply silicone grease to the sliding surface of the brake
lever pivot bolt.
Tighten:
Torque - Brake Lever Pivot Bolt: 1.2 N·m (0.12 kgf·m, 11
in·lb)
Brake Lever Pivot Bolt Nut: 5.9 N·m (0.60 kgf·m,
52 in·lb)
Assemble the reservoir [A] and the bracket [B] as shown
in the figu ...
Coupling Bearing Inspection
Since the coupling bearing is made to extremely close
tolerances, the clearance can not normally be measured.
NOTE
It is not necessary to remove the coupling bearing for
inspection. If the bearing is removed, it will need to be
replaced with a new one.
Turn the bearing in the coupling b ...