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]
Brake Lever Adjuster
There is an adjuster on the brake
lever. The adjuster has 6 positions so
that the released lever position can be
adjusted to suit the operator’s hands.
Push the lever forward and turn the adjuster
to align the number with the mark
on the lever holder. The distance from
the grip to the rel ...
Cam Wear Inspection
Remove the camshafts (see Camshaft Removal).
Measure the height [A] of each cam with a micrometer.
If the cams are worn down past the service limit, replace
the camshaft.
Cam Height
Standard:
Exhaust 35.043 35.157 mm
(1.3796 1.3841 in.)
Intake 38.243 38.357 mm
(1.5056 1.5101 in. ...
Loading and accessories information
WARNINGIncorrect loading, improper installation
or use of accessories,
or modification of your motorcyclemay
result in an unsafe riding
condition. Before you ride the
motorcycle, make sure it is not
overloaded and that you have
followed these instructions.
With the ...