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 Intake Duct Disassembly
(Other than US, CA and CAL Models)
Remove:
Air Intake Duct (see Air Intake Duct Removal)
Seal [A] and Screen [B]
Turn the air intake valve actuator [C] counterclockwise
(90°).
Remove the shaft [A] of the air intake valve actuator.
Remove:
Pad [A]
Screws [B]
Air Intake Valve [C]
...
Coupling Bearing Removal
Remove:
Coupling
Grease Seal
Circlip [A]
Special Tool - Inside Circlip Pliers: 57001-143
Remove the bearing [A] by tapping from the wheel side.
Special Tool - Bearing Driver Set [B]: 57001-1129
...
Front Fork Inspection
Holding the brake lever, pump the
front fork up and down several times
to inspect smooth stroke.
Visually inspect the front fork for oil
leakage, scoring or scratches on the
outer surface of the inner tube.
If any doubt about the front fork, it
should be checked by an authorized
K ...