- •LIST OF ABBREVIATIONS
- •New Ignition Interlock Sidestand System
- •Current Ignition Interlock Sidestand System
- •Materials of Semi-Conductor and Emitting Color
- •Units of Mass:
- •Units of Volume:
- •Units of Force:
- •Units of Length:
- •Units of Torque:
- •Units of Pressure:
- •Units of Speed:
- •Units of Power:
- •Periodic Inspection:
- •Periodic Replacement Parts:
- •Basic Torque for General Fasteners
- •Throttle Grip Free Play
- •Idle Speed
- •Engine Vacuum
- •Water and Coolant Mixture Ratio (when shipping)
- •Valve Clearance
- •Clutch Lever Free Play
- •Engine Oil
- •Tread Depth
- •Air Pressure (when cold)
- •Chain Slack
- •Drive Chain 20-link Length
- •Standard Chain
- •Pad Lining Thickness
- •Sample Diagnosis Sheet
- •Poor Running at Low Speed
- •Poor Running or No Power at High Speed:
- •Wiring Connection
- •Idle Speed
- •Wiring Connection
- •Main Throttle Sensor Resistance
- •Inlet Air Pressure Sensor Output Voltage
- •Inlet Air Temperature Sensor Output Voltage
- •Water Temperature Sensor Output Voltage
- •Atmospheric Pressure Sensor Input Voltage
- •Output Voltage at Sensor
- •Wiring Connection
- •Wiring Connection
- •Throttle Sensor Resistance
- •Stick Coil Input Voltage at ECU
- •Input Voltage at ECU
- •Subthrottle Valve Actuator Resistance
- •Subthrottle Valve Actuator Input Voltage
- •Input Voltage at Actuator
- •FI Indicator LED Light Check
- •ECU Grounding Inspection
- •ECU Power Source Inspection
- •Testing Relay
- •Fuel Pressure
- •Fuel Pressure (idling)
- •Amount of Fuel Flow
- •Testing Relay
- •Injector Power Source Voltage at ECU
- •Output Voltage at Injector Connector
- •Injector Wiring Inspection
- •Choke Lever Free Play
- •Radiator Cap Relief Pressure
- •Thermostat Valve Opening Temperature
- •Camshaft Journal, Camshaft Cap Clearance
- •Camshaft Journal Diameter
- •Camshaft Runout
- •Cylinder Compression
- •Cylinder Head Warp
- •Valve/Valve Guide Clearance (Wobble Method)
- •Valve Seating Surface Outside Diameter
- •Valve Seating Surface Width
- •Cylinder Inside Diameter
- •Piston Diameter
- •Piston Ring/Groove Clearance
- •Piston Ring Groove Width
- •Piston Ring Thickness
- •Piston Ring End Gap
- •Clutch Plate Assembly
- •Friction Plate Thickness
- •Friction and Steel Plate Warp
- •Clutch Spring Free Length
- •Oil Pressure
- •Connecting Rod Bend
- •Connecting Rod Twist
- •Connecting Rod Big End Side Clearance
- •Crankpin Diameter
- •Crankpin Diameter Marks
- •Connecting Rod Big End Inside Diameter Marks
- •Crankshaft Side Clearance
- •Crankshaft Runout
- •Crankshaft Main Journal Diameter
- •Crankshaft Main Journal Diameter Marks
- •Crankcase Main Bearing Inside Diameter Marks
- •Shift Fork Ear Thickness
- •Gear Groove Width
- •Shift Fork Guide Pin Diameter
- •Shift Drum Groove Width
- •Rim Runout
- •Axle Runout/100 mm (3.94 in.)
- •Balance Weight
- •Link Pin Outside Diameter
- •Link Plates Outside Width
- •Rear Sprocket Warp
- •Pedal Position
- •Front Disc Thickness
- •Rear Disc Thickness
- •Disc Runout
- •Oil Level (fully compressed, without spring)
- •Fork Spring Free Length
- •Rebound Damping Adjustment
- •Spring Preload Setting
- •Spring Preload Adjustment
- •Table 1 Alternator Output Voltage
- •Table 2 Stator Coil Resistance
- •Rectifier Circuit Inspection
- •Charging Voltage
- •Crankshaft Sensor Peak Voltage
- •Connections:
- •Camshaft Position Sensor Peak Voltage
- •Ignition Coil Winding Resistance
- •Primary Lead Connection
- •Connection:
- •Condition:
- •Starter Motor Brush Length
- •Commutator Diameter
- •Testing Relay
- •Testing Turn Signal Relay
- •Water Temperature Sensor
- •Fuel Level Sensor Resistance
- •Connections:
- •Fuse Circuit Inspection
- •Relay Circuit Inspection (with the battery disconnected)
- •Relay Circuit Inspection (with the battery connected)
- •Diode Circuit Inspection
- •Foreword
- •General Information
- •Battery Ground
- •Edges of Parts
- •Solvent
- •Cleaning vehicle before disassembly
- •Arrangement and Cleaning of Removed Parts
- •Storage of Removed Parts
- •Inspection
- •Replacement Parts
- •Assembly Order
- •Tightening Sequence
- •Tightening Torque
- •Force
- •Gasket, O-ring
- •Liquid Gasket, Locking Agent
- •Press
- •Ball Bearing and Needle Bearing
- •Oil Seal, Grease Seal
- •Circlips, Cotter Pins
- •Lubrication
- •Direction of Engine Rotation
- •Electrical Wires
- •ZR750–J1 Left Side View:
- •ZR750–J1 Right Side View:
- •Subthrottle Control System
- •Outline
- •Outline
- •Due Position of LED Installation
- •Honeycomb Type Catalytic Converter
- •Prefixes for Units:
- •Units of Temperature:
- •Periodic Maintenance
- •Steering Stem Nut Wrench:
- •Fuel System (DFI)
- •Fuel Hose and Connection Inspection
- •Throttle Control System Inspection
- •Engine Vacuum Synchronization Inspection
- •Air Cleaner Element Cleaning
- •Cooling System
- •Radiator Hose and Connection Inspection
- •Coolant Change
- •Engine Top End
- •Valve Clearance Inspection
- •Clutch
- •Engine Lubrication System
- •Engine Oil Change
- •Wheels/Tires
- •Tire Wear Inspection
- •Air Pressure Inspection
- •Final Drive
- •Drive Chain Slack Inspection
- •Brakes
- •Rear Brake Light Switch Connections:
- •Caliper Fluid Seal Damage
- •Brake Line Bleeding
- •Suspension
- •Steering
- •Steering Adjustment
- •Electrical System
- •General Lubrication
- •Lubrication
- •Nut, Bolt, and Fastener Tightness
- •Fuel System (DFI)
- •Terminal Names
- •Part Name
- •Oil Pressure Gauge:
- •DFI Servicing Precautions
- •Outline
- •Outline
- •DFI Diagnosis Flow Chart
- •Inquiries to Rider
- •Inquiries to Rider
- •DFI System Troubleshooting Guide
- •Self-diagnosis Outline
- •Self-diagnosis Outline
- •Self-diagnosis Procedures
- •Self-diagnosis Procedures
- •Service Code Clearing Procedures
- •How to Read Service Codes
- •How to Read Service Codes
- •How to Erase Service Codes
- •How to Erase Service Codes
- •Service Code Table
- •Service Code Table
- •Notes:
- •Backups
- •Backups
- •Main Throttle Sensor Removal/Adjustment
- •Input Voltage Inspection
- •Resistance Inspection
- •CAUTION
- •Removal
- •Installation
- •Input Voltage Inspection
- •Output Voltage Inspection
- •Removal/Installation
- •Output Voltage Inspection
- •Removal/Installation
- •Output Voltage Inspection
- •CAUTION
- •Removal
- •Input Voltage Inspection
- •Crankshaft Sensor Inspection
- •Camshaft Position Sensor Removal/Installation
- •Camshaft Position Sensor Inspection
- •Input Voltage Inspection
- •Removal
- •Installation
- •Inspection
- •Subthrottle Sensor Removal/Adjustment
- •Input Voltage Inspection
- •Removal/Installation
- •Input Voltage Inspection
- •Subthrottle Valve Actuator Removal
- •Audible Inspection
- •Input Voltage Inspection
- •Inspection Flow Chart
- •CAUTION
- •ECU Power Source Circuit
- •ECU Fuse Installation
- •ECU Main Relay Removal
- •Fuel Pressure Inspection
- •Fuel Flow Rate Inspection
- •Fuel Pump Removal
- •Operation Inspection
- •Operating Voltage Inspection
- •Pressure Regulator Removal
- •Pump Screen, Fuel Filter Cleaning
- •Fuel Pump Relay Removal
- •Removal/Installation
- •Choke Lever Operation
- •Throttle Body Assy Removal
- •Throttle Body Assy Disassembly
- •Throttle Body Assy Assembly
- •Air Cleaner Oil Draining
- •Fuel Tank Removal
- •Fuel Tank Cleaning
- •Cooling System
- •Bearing Driver:
- •Coolant Level Inspection
- •Cooling System Flushing
- •Water Pump Housing Disassembly
- •Water Pump Housing Assembly
- •Radiator and Radiator Fan Removal
- •CAUTION
- •Engine Top End
- •Exhaust System
- •Compression Gauge:
- •Camshaft Chain Tensioner Removal
- •Cylinder Compression Measurement
- •Cylinder Head Installation
- •Valve Guide Installation
- •Seat Cutter Operation Care:
- •Cylinder Installation
- •WARNING
- •Clutch
- •Clutch Holder:
- •Clutch Lever Adjustment
- •Release Shaft Removal
- •Engine Lubrication System
- •WARNING
- •Oil Pressure Measurement
- •Engine Removal/Installation
- •Crankshaft/Transmission
- •Bearing Puller:
- •Crankcase Splitting
- •Crankcase Assembly
- •Crankshaft Installation
- •Connecting Rod Installation
- •Wheels/Tires
- •Bearing Driver Set:
- •Front Wheel Installation
- •Axle Inspection
- •Tire Installation
- •Tire Repair
- •Hub Bearing Inspection
- •Final Drive
- •Bearing Driver Set:
- •Coupling Bearing Inspection
- •Brakes
- •Jack:
- •Brake Lever Position Adjustment
- •Brake Pedal Position Adjustment
- •Caliper Holder Shaft Wear
- •Rear Master Cylinder Disassembly
- •Brake Hose Removal/Installation
- •Suspension
- •Fork Cylinder Holder Handle:
- •Swingarm Installation
- •Swingarm Bearing, Sleeve Inspection
- •Steering
- •Steering Stem Nut Wrench:
- •Frame
- •Electrical System
- •Rotor Puller, M16/M18/M20/M22 × 1.5 :
- •Battery Removal
- •Initial Charge
- •Precautions
- •Alternator Inspection
- •Charging System Circuit
- •WARNING
- •Special Tool -
- •Crankshaft Sensor Peak Voltage Inspection
- •Stick Coil (Ignition Coil together with Spark Plug Cap) Removal
- •Stick Coil Primary Peak Voltage
- •IC Igniter Inspection
- •Ignition System Circuit
- •Starter Motor Removal
- •Starter Motor Installation
- •Electric Starter Circuit
- •Headlight/Tail Light Circuit (CA, AS)
- •Headlight/Tail Light Circuit (Other than CA, AS)
- •Turn Signal Light Circuit
- •Turn Signal Light Bulb Replacement
- •Radiator Fan Circuit
- •Electronic Combination Meter Unit Inspection
- •Meter Circuit
- •Rear Brake Light Switch Connections
- •Side Stand Switch Connections
- •Neutral Switch Connections
- •Oil Pressure Switch Connections*
- •Special Tool -
- •Junction Box Internal Circuit
- •30 A Main Fuse Removal
- •15 A ECU Fuse Removal
- •Appendix
- •NOTE
- •Starter motor not rotating:
- •No fuel flow:
- •Engine flooded:
- •No spark; spark weak:
- •Fuel/air mixture incorrect:
- •Compression Low:
- •Poor Running at Low Speed:
- •Spark weak:
- •Fuel/air mixture incorrect:
- •Compression low:
- •Other:
- •Poor Running or No Power at High Speed:
- •Firing incorrect:
- •Fuel/air mixture incorrect:
- •Compression low:
- •Knocking:
- •Miscellaneous:
- •Overheating:
- •Firing incorrect:
- •Muffler overheating:
- •Fuel/air mixture incorrect:
- •Compression high:
- •Engine load faulty:
- •Lubrication inadequate:
- •Gauge incorrect:
- •Coolant incorrect:
- •Cooling system component incorrect:
- •Over Cooling:
- •Gauge incorrect:
- •Cooling system component incorrect:
- •Clutch Operation Faulty:
- •Clutch slipping:
- •Clutch not disengaging properly:
- •Gear Shifting Faulty:
- •Jumps out of gear:
- •Overshifts:
- •Abnormal Engine Noise:
- •Knocking:
- •Piston slap:
- •Valve noise:
- •Other noise:
- •Abnormal Drive Train Noise:
- •Clutch noise:
- •Transmission noise:
- •Drive line noise:
- •Abnormal Frame Noise:
- •Front fork noise:
- •Rear shock absorber noise:
- •Disc brake noise:
- •Other noise:
- •Oil Pressure Warning Light Goes On:
- •Exhaust Smokes Excessively:
- •White smoke:
- •Black smoke:
- •Brown smoke:
- •Handlebar hard to turn:
- •Handlebar shakes or excessively vibrates:
- •Handlebar pulls to one side:
- •Shock absorption unsatisfactory:
- •Battery Trouble:
- •Battery discharged:
- •Battery overcharged:
CRANKSHAFT/TRANSMISSION 9-1
Crankshaft/Transmission
Table of Contents
Exploded View................................... |
9-2 |
Specifications .................................... |
9-6 |
Special Tools and Sealant ................. |
9-9 |
Crankcase Splitting............................ |
9-10 |
Crankcase Splitting ...................... |
9-10 |
Crankcase Assembly ................... |
9-10 |
Crankshaft and Connecting Rods...... |
9-13 |
Crankshaft Removal .................... |
9-13 |
Crankshaft Installation ................. |
9-13 |
Connecting Rod Removal............ |
9-13 |
Connecting Rod Installation ......... |
9-13 |
Crankshaft/Connecting Rod |
|
Cleaning .................................... |
9-16 |
Connecting Rod Bend.................. |
9-17 |
Connecting Rod Twist .................. |
9-17 |
Connecting Rod Big End Side |
|
Clearance.................................. |
9-17 |
Connecting Rod Big End Bearing |
|
Insert/Crankpin Wear ................ |
9-18 |
Crankshaft Side Clearance .......... |
9-19 |
Crankshaft Runout....................... |
9-20 |
Crankshaft Main Bearing |
|
Insert/Journal Wear................... |
9-20 |
Starter Motor Clutch .......................... |
9-22 |
Starter Motor Clutch |
|
Removal/Installation.................. |
9-22 |
Starter Motor Clutch Inspection ... |
9-22 |
|
|
Starter Motor Clutch Disassembly |
9-22 |
|
|
Starter Motor Clutch Assembly .... |
9-22 |
|
|
Transmission ..................................... |
9-23 |
|
|
Shift Pedal Removal .................... |
9-23 |
|
|
Shift Pedal Installation ................. |
9-23 |
|
|
External Shift Mechanism |
|
|
|
Removal.................................... |
9-24 |
|
|
External Shift Mechanism |
|
|
|
Installation ................................. |
9-25 |
|
|
External Shift Mechanism |
|
|
|
Inspection.................................. |
9-25 |
|
|
.......Transmission Shaft Removal |
9-26 |
9 |
|
Transmission Shaft Installation .... |
9-26 |
|
|
|
|
||
Transmission Shaft Disassembly. |
9-26 |
|
|
Transmission Shaft Assembly...... |
9-27 |
|
|
Shift Drum and Fork Removal...... |
9-30 |
|
|
Shift Drum and Fork Installation... |
9-30 |
|
|
Shift Drum Disassembly............... |
9-30 |
|
|
Shift Drum Assembly ................... |
9-30 |
|
|
Shift Fork Bending ....................... |
9-31 |
|
|
Shift Fork/Gear Groove Wear ...... |
9-31 |
|
|
Shift Fork Guide Pin/Drum |
|
|
|
Groove Wear............................. |
9-31 |
|
|
Gear Dog and Gear Dog Hole |
|
|
|
Damage..................................... |
9-31 |
|
|
9-2 CRANKSHAFT/TRANSMISSION
Exploded View
CRANKSHAFT/TRANSMISSION 9-3
Exploded View
|
|
|
|
|
|
|
No. |
Fastener |
|
Torque |
|
Remarks |
|
N·m |
kgf·m |
ft·lb |
||||
|
|
|
||||
1 |
Breather plate bolts |
9.8 |
1.0 |
87 in·lb |
L |
|
2 |
Crankcase bolts (M9, L = 81 mm) |
42 |
4.3 |
31 |
MO, S |
|
3 |
Crankcase bolts (M9, L = 95 mm) |
42 |
4.3 |
31 |
MO, S |
|
4 |
Crankcase bolts (M8) |
27 |
2.8 |
20 |
S |
|
5 |
Crankcase bolts (M7) |
20 |
2.0 |
14 |
S |
|
6 |
Crankcase bolts (M6) |
12 |
1.2 |
104 in·lb |
S |
|
7 |
Starter motor clutch bolts |
12 |
1.2 |
104 in·lb |
L |
|
8 |
Oil pipe holder bolts |
13 |
1.3 |
113 in·lb |
L |
|
9 |
Shift drum bearing holder screw |
5.4 |
0.55 |
48 in·lb |
L |
|
10 |
Shift drum bearing holder bolt |
13 |
1.3 |
113 in·lb |
L |
|
11 |
Connecting rod big end nuts |
see the text |
← |
← |
← |
|
12 |
Crankshaft position rotor bolt |
40 |
4.1 |
30 |
|
|
13 |
Oil pressure switch |
15 |
1.5 |
11 |
SS |
|
14 |
Oil pressure switch terminal bolt |
1.5 |
0.15 |
13 in·lb |
|
|
15 |
Oil passage plugs |
20 |
2.0 |
14 |
L |
|
16 |
Crankshaft sensor cover bolts |
11 |
1.1 |
95 in·lb |
|
17. Do not apply any grease or oil. EO: Apply engine oil.
G: Apply grease.
L: Apply a non-permanent locking agent.
LG: Apply liquid gasket (Kawasaki Bond: 92104–1066).
M: Apply molybdenum disulfide grease.
MO: Apply molybdenum disulfide oil.
(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1) R: Replacement Parts
S: Tightening the fasteners following the specified sequence.
SS: Apply silicone sealant (Kawasaki Bond: 56019–120).
9-4 CRANKSHAFT/TRANSMISSION
Exploded View
CRANKSHAFT/TRANSMISSION 9-5
Exploded View
|
|
|
|
|
|
|
No. |
Fastener |
|
Torque |
|
Remarks |
|
N·m |
kgf·m |
ft·lb |
||||
|
|
|
||||
1 |
Shift pedal mounting bolt |
34 |
3.5 |
25 |
L |
|
2 |
Gear positioning lever bolt |
12 |
1.2 |
104 in·lb |
|
|
3 |
Shift shaft return spring pin |
29 |
3.0 |
22 |
L |
|
4 |
Shift drum cam holder bolt |
12 |
1.2 |
104 in·lb |
L |
|
5 |
Footpeg bracket bolts |
34 |
3.5 |
25 |
L |
|
6 |
Shift lever bolt |
6.9 |
0.70 |
61 in·lb |
|
|
7 |
Tie-rod locknuts |
6.9 |
0.70 |
61 in·lb |
|
|
8 |
Neutral switch |
15 |
1.5 |
11 |
|
EO: Apply engine oil.
G: Apply grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts
9-6 CRANKSHAFT/TRANSMISSION
Specifications
|
|
|
|
|
|
|
Item |
|
|
|
|
Standard |
Service Limit |
Crankshaft, Connecting Rods: |
|
|
|
|
|
|
Connecting rod bend |
|
|
|
|
– – – |
TIR 0.2/100 mm |
|
|
|
|
|
|
(0.008/3.94 in.) |
Connecting rod twist |
|
|
|
|
– – – |
TIR 0.2/100 mm |
|
|
|
|
|
|
(0.008/3.94 in.) |
Connecting rod big end side clearance |
0.13 0.38 mm |
0.58 mm |
||||
|
|
|
|
(0.0051 |
0.0150 in.) |
(0.023 in.) |
Connecting rod big end bearing insert/crankpin |
0.041 0.071 mm |
0.11 mm |
||||
clearance |
|
|
|
(0.0016 |
0.0028 in.) |
(0.0043 in.) |
Crankpin diameter: |
|
|
|
34.984 |
35.000 mm |
34.97 mm |
|
|
|
|
(1.3773 |
1.3780 in.) |
(1.3768 in.) |
Marking |
None |
34.984 |
34.992 mm |
– – – |
||
|
|
|
|
(1.3773 |
1.3776 in.) |
|
|
|
|
|
34.993 |
35.000 mm |
– – – |
|
|
|
|
|||
|
|
|
|
(1.3777 |
1.3780 in.) |
|
Connecting rod big end inside diameter: |
38.000 |
38.016 mm |
– – – |
|||
|
|
|
|
(1.4961 |
1.4967 in.) |
|
Marking |
None |
38.000 |
38.008 mm |
– – – |
||
|
|
|
|
(1.4961 |
1.4964 in.) |
|
|
|
|
|
38.009 |
38.016 mm |
– – – |
|
|
|
|
|||
|
|
|
|
(1.4964 |
1.4967 in.) |
|
Connecting rod big end bearing insert thickness: |
|
|
|
|||
|
Brown |
1.475 1.480 mm |
– – – |
|||
|
|
|
|
(0.05807 0.05827 in.) |
|
|
|
Black |
1.480 1.485 mm |
– – – |
|||
|
|
|
|
(0.05827 0.05846 in.) |
|
|
|
Blue |
1.485 1.490 mm |
– – – |
|||
|
|
|
|
(0.05846 0.05866 in.) |
|
Connecting rod big end bearing insert selection:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Con-rod Big End |
|
Crankpin |
|
Bearing Insert |
|
|||||||
|
Bore Diameter |
|
Diameter |
|
|
|
|
|
|
||||
|
Marking |
|
Marking |
|
Size Color |
|
Part Number |
|
|||||
|
None |
|
|
|
|
|
Brown |
|
92139–1110 |
|
|||
|
|
|
|
|
|
|
|||||||
|
|
|
|
|
|
|
|
|
|
|
|
||
|
None |
|
None |
|
Black |
|
92139–1109 |
|
|||||
|
|
|
|
|
|
|
|
|
|
|
|
||
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
||
|
|
|
|
|
None |
|
Blue |
|
92139–1108 |
|
|||
|
|
|
|
|
|
|
|||||||
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
||||
Connecting Rod Bolt Stretch: |
|
|
|
|
|
|
|
|
|
||||
|
|
(Usable Range) |
|
|
|
|
|
|
|||||
|
New connecting rod |
|
0.24 0.36 mm |
|
– – – |
|
|||||||
|
|
|
|
|
|
|
|
|
(0.0094 0.0142 in.) |
|
|
|
|
|
Used connecting rod |
|
0.20 0.32 mm |
|
– – – |
|
|||||||
|
|
|
|
|
|
|
|
|
(0.0079 0.0126 in.) |
|
|
|
CRANKSHAFT/TRANSMISSION 9-7
Specifications
|
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Item |
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Standard |
Service Limit |
Crankshaft side clearance |
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0.05 0.20 mm |
0.40 mm |
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(0.0020 |
0.0079 in.) |
(0.0157 in.) |
Crankshaft runout |
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TIR 0.02 mm (0.0008 in.) or |
TIR 0.05 mm |
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less |
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(0.0020 in.) |
Crankshaft main bearing insert/journal clearance |
0.020 0.044 mm |
0.07 mm |
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(0.0008 |
0.0017 in.) |
(0.0028 in.) |
Crankshaft main journal diameter: |
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32.984 |
33.000 mm |
32.96 mm |
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(1.2986 |
1.2992 in.) |
(1.2976 in.) |
Marking |
None |
32.984 |
32.992 mm |
– – – |
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(1.2986 |
1.2989 in.) |
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1 |
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32.993 |
33.000 mm |
– – – |
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(1.2989 |
1.2992 in.) |
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Crankcase main bearing inside diameter: |
36.000 |
36.016 mm |
– – – |
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(1.4173 |
1.4179 in.) |
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Marking |
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36.000 |
36.008 mm |
– – – |
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(1.4173 |
1.4176 in.) |
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None |
36.009 |
36.016 mm |
– – – |
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(1.4177 |
1.4179 in.) |
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Crankshaft main bearing insert thickness: |
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Brown |
1.490 1.494 mm |
– – – |
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(0.0587 |
0.0588 in.) |
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Black |
1.494 1.498 mm |
– – – |
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(0.0588 |
0.0590 in.) |
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Blue |
1.498 1.502 mm |
– – – |
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(0.0590 |
0.0591 in.) |
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Crankshaft main bearing insert selection: |
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Crankcase Main |
Crankshaft Main |
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Bearing Insert* |
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Bearing Inside |
Journal Diameter |
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Diameter Marking |
Marking |
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Size Color |
Part Number |
Journal Nos. |
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1 |
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Brown |
92028–1868 |
3, 5 |
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92028–1829 |
1, 2, 4 |
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None |
1 |
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Black |
92028–1867 |
3, 5 |
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None |
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92028–1828 |
1, 2, 4 |
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None |
None |
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Blue |
92028–1866 |
3, 5 |
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92028–1827 |
1, 2, 4 |
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*The bearing inserts for Nos. 1, 2 and 4 journals have an oil groove, respectively.
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Transmission: |
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Shift fork ear thickness |
5.9 6.0 mm |
5.8 mm |
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(0.232 |
0.236 in.) |
(0.228 |
in.) |
Gear groove width |
6.05 6.15 mm |
6.25 mm |
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(0.238 |
0.242 in.) |
(0.246 |
in.) |
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9-8 CRANKSHAFT/TRANSMISSION
Specifications
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Item |
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Standard |
Service Limit |
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Shift fork guide pin diameter |
6.9 7.0 mm |
6.8 |
mm |
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(0.272 |
0.276 in.) |
(0.268 |
in.) |
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Shift drum groove width |
7.05 7.20 mm |
7.3 |
mm |
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(0.278 |
0.283 in.) |
(0.287 |
in.) |