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.
Coolant Level Inspection
NOTE
Check the level when the engine is cold (room or ambient
temperature).
Check the coolant level in the reserve tank [A] with the
motorcycle held perpendicular (Do not use the sidestand).
If the coolant level is lower than the “L” level line [B], remove
the upper fairing assembly (s ...
Radiator Hose and Pipe Inspection (coolant leak, damage, installation
condition)
The high pressure inside the radiator hose can cause
coolant to leak [A] or the hose to burst if the line is not
properly maintained.
Visually inspect the hoses for signs of deterioration.
Squeeze the hoses. A hose should not be hard and
brittle, nor should it be soft or swollen.
Repl ...
Exhaust System Identification
Exhaust Pipe Mark Position [A]
Premuffler Chamber Mark Position [A]
Muffler Body Mark Position [A]
Premuffler Chamber [A] with Hole [B] for Oxygen Sensor [C]
Honeycomb Type Catalyst Position [A]
Specifications
...