CRANKSHAFT/PISTON/CYLINDER
12-3
SERVICE INFORMATION
GENERAL
• The crankcase must be separated to service the crankshaft, cylinder and piston/connecting rod. Refer to procedures for
crankcase separation (page 11-5).
• Mark and store the connecting rods, bearing caps and bearing inserts to be sure of their correct locations for reassem-
bly.
• The crankpin and main journal bearing inserts are select fit and are identified by color codes. Select replacement bear-
ings from the code tables. After selecting new bearings, recheck the oil clearance with a plastigauge. Incorrect oil clear-
ance can cause major engine damage.
• Clean the oil jets 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 – 0.30 (0.006 – 0.012)
0.35 (0.014)
Crankpin bearing oil clearance
0.028 – 0.052 (0.0011 – 0.0020)
0.06 (0.002)
Main journal bearing oil clearance
0.020 – 0.038 (0.0008 – 0.0015)
0.05 (0.002)
Runout
–
0.05 (0.002)
Piston, piston
rings
Piston O.D. at 6 (0.2) from bottom
66.965 – 66.985 (2.6364 – 2.6372)
66.90 (2.634)
Piston pin bore I.D.
16.002 – 16.008 (0.6300 – 0.6302)
16.02 (0.631)
Piston pin O.D.
15.994 – 16.000 (0.6297 – 0.6299)
15.98 (0.629)
Piston-to-piston pin clearance
0.002 – 0.014 (0.0001 – 0.0006)
0.04 (0.002)
Piston ring end
gap
Top
0.10 – 0.20 (0.004 – 0.008)
0.4 (0.02)
Second
0.21 – 0.31 (0.008 – 0.012)
0.5 (0.02)
Oil
(side rail)
0.2 – 0.7 (0.01 – 0.03)
1.0 (0.04)
Piston ring-to-ring
groove clearance
Top
0.030 – 0.060 (0.0012 – 0.0024)
0.10 (0.004)
Second
0.015 – 0.050 (0.0006 – 0.0020)
0.08 (0.003)
Cylinder
I.D.
67.000 – 67.015 (2.6378 – 2.6384)
67.10 (2.642)
Out of round
–
0.10 (0.004)
Taper
–
0.10 (0.004)
Warpage
–
0.10 (0.004)
Cylinder-to-piston clearance
0.015 – 0.050 (0.0006 – 0.0022)
0.10 (0.004)
Connecting rod small end I.D.
16.030 – 16.044 (0.6311 – 0.6317)
16.05 (0.632)
Connecting rod-to-piston pin clearance
0.030 – 0.05 (0.0012 – 0.0020)
0.07 (0.003)
Connecting rod bearing cap
nut
26 N·m (2.7 kgf·m, 19 lbf·ft)
Apply engine oil to the threads and seating
surface.
Crankcase 8 mm bolt (main
journal bolt)
15 N·m (1.5 kgf·m, 11 lbf·ft) + 120
°
See page 11-17
Replace with a new one.
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys.
email: [email protected]