If the guide pin on any shift fork is less than the service limit, the fork must be replaced.
Shift Fork Guide Pin Diameter
Standard: 6.9 
7.0 mm (0.272
0.276 in.)
Service Limit: 6.8 mm (0.268 in.)
If any shift drum groove is worn over the service limit, the drum must be replaced.
Shift Drum Groove Width
Standard: 7.05 
7.20 mm (0.278
0.283 in.)
Service Limit: 7.3 mm (0.287 in.)
Shift Fork/Gear Groove Wear Inspection
Gear Dog and Gear Dog Hole
Damage InspectionConnecting Rod Big End
Bearing Insert/Crankpin Wear Inspection
Remove the connecting rod big end (see Connecting Rod
Removal).
Cut strips of plastigage to crankpin width. Place a strip
on the crankpin parallel to the crankshaft installed in the
correct position.
Tighten the connecting rod big end nuts to the specified
torque (see Connecting Rod I ...
Brake Fluid Leak (Brake Hose and Pipe) Inspection
For KIBS equipped models, remove the fuel tank (see
Fuel Tank Removal in the Fuel System (DFI) chapter).
Apply the brake lever or pedal and inspect the brake fluid
leak from the brake hoses [A], pipes (KIBS equipped models)
[B] and fittings [C].
If the brake fluid leaked from any posit ...
Oil Pan Installation
If the oil filter holder bolt [A] was removed, tighten it.
Apply a non-permanent locking agent to the threads of
the oil filter holder bolt.
Torque - Oil Filter Holder Bolt: 35 N·m (3.6 kgf·m, 26 ft·lb)
Replace the O-rings [B] with new ones, and apply grease
to them.
Install the O-ri ...