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]
Handlebar Removal
Remove:
Steering Damper (see Steering Damper Removal)
Clutch Lever Clamp Bolts [A]
Clutch Lever Assembly [B]
Left Switch Housing [C]
Handlebar Weight [D]
Left Handlebar Grip [E]
Remove:
Front Master Cylinder [A] (see Front Master Cylinder Removal
in the Brakes chapter)
...
Crankshaft Sensor Inspection
Disconnect the crankshaft sensor lead connector (see
Crankshaft Sensor Removal).
Set the hand tester [A] to the × 10 Ω range and connect it
to the crankshaft sensor lead connector [B].
Special Tool - Hand Tester: 57001-1394
Crankshaft Sensor Resistance
Connections:
Meter (+ ...
Oil Pump Installation
Install the outer rotor [A] into the crankcase.
Assemble:
Oil (Water) Pump Shaft [B]
Pin [C]
Inner Rotor [D]
To prevent dropping, apply grease to the pin.
Install the inner rotor assembly into the crankcase.
Fit the slot [E] onto the projection [F].
Replace the O-ring [A ...