15-3
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CRANKSHAFT/PISTON/CYLINDER
SERVICE INFORMATION
GENERAL
This motorcycle provides cracking connecting rods. Be sure to install each part in its original position, as noted during removal. Do
not reuse the improperly installed connecting rod and bearing cap, because their mating surfaces are damaged.
• The crankcase must be separated to service the following:
– Crankshaft (page 15-5)
– Piston/cylinder (page 15-14)
• Mark and store the connecting rods, bearing caps and bearing inserts to be sure of their correct locations for reassembly.
• The crankpin and main journal bearing inserts are select fit and are identified by color codes. Select replacement bearings from
the code tables. After selecting new bearings, recheck the oil clearance with a plastigauge. Incorrect oil clearance can cause
major engine damage.
• Clean the oil passages in the upper crankcase with compressed air before installing the pistons.
SPECIFICATIONS
Unit: mm (in)
TORQUE VALUES
ITEM STANDARD SERVICE LIMIT
Crankshaft Connecting rod side clearance 0.15 – 0.35 (0.006 – 0.014) 0.45 (0.018)
Runout Right side – 0.03 (0.001)
Left side – 0.03 (0.001)
Main journal bearing oil clearance 0.019 – 0.037 (0.0007 – 0.0015) 0.05 (0.002)
Cylinder I.D. 73.000 – 73.015 (2.8740 – 2.8746) 73.07 (2.877)
Out-of-round – 0.10 (0.004)
Taper – 0.10 (0.004)
Warpage – 0.10 (0.004)
Piston, piston
rings
Piston O.D. at 13 mm (0.5 in) from
bottom
72.976 – 72.990 (2.8731 – 2.8736) 72.970 (2.8728)
Piston pin bore I.D. 18.010 – 18.013 (0.7091 – 0.7092) 18.023 (0.7096)
Piston pin O.D. 17.996 – 18.000 (0.7085 – 0.7087) 17.988 (0.7082)
Piston-to-piston pin clearance 0.010 – 0.017 (0.0004 – 0.0007) 0.035 (0.0014)
Piston ring end
gap
Top 0.15 – 0.30 (0.006 – 0.012) 0.6 (0.02)
Second 0.30 – 0.42 (0.012 – 0.017) 0.6 (0.02)
Oil (side rail) 0.20 – 0.70 (0.008 – 0.028) 0.8 (0.03)
Piston ring-to-ring
groove clearance
Top 0.035 – 0.080 (0.0014 – 0.0032) 0.15 (0.006)
Second 0.030 – 0.055 (0.0012 – 0.0022) 0.13 (0.005)
Cylinder-to-piston clearance 0.010 – 0.039 (0.0004 – 0.0015) 0.05 (0.002)
Connecting rod small end I.D. 17.964 – 17.977 (0.7072 – 0.7078) 17.985 (0.7081)
Crankpin bearing oil clearance 0.026 – 0.044 (0.0010 – 0.0017) 0.05 (0.002)
ITEM Q'TY
THREAD TORQUE
REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Crankpin bearing cap bolt 4 6 10 (1.0, 7) + 90° See page 15-7
Replace with a new one.
Apply engine oil to the threads and
seating surface.
Crankcase main journal bolt
(retightening)
6 9 20 (2.0, 15) + 120° See page 15-9
Apply engine oil to the threads and
seating surface.
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