Like this Manual?SAFETY FIRST: Protective gloves and eyewear are recommended at this point.
Crankshaft
Split the crankcases. See the crankcase Crankcases topic for more information.
Use a press to remove the crankshaft. Do not allow the crank to fall out of the right crankcase half.
When installing the crankshaft first lubricate the journals with fresh engine oil. Press the crankshaft into the right crankcase half.
Assemble the crankcases. See the Crankcases topic for more information.
Connecting Rods
Mark the connecting rods and big end caps so that they can be returned to their original positions.
Loosen the connecting rod nuts evenly with a 12 mm socket.
Clean the connecting rods and crankshaft oil passages with a high flash point solvent and compressed air.
NOTE: Always wear safety glasses when using compressed air and never point it directly at yourself or anyone else.
When installing the big end caps onto the rods make sure the grooves are on the same side. If installing new rods onto the crankshaft make sure to select the correct bearing inserts. See the inspection section below for more information.
Lubricate all bearing inserts for the connecting rods with molybdenum solution. Also apply moly solution to the connecting rod bolt and nut threads as well as the bolt and nut seating surfaces.
Molybdenum solution – 1 to 1 ratio mixture of fresh engine oil and molybdenum disulfide grease.
When the installing the connecting rods position the rods so the out marks are facing towards the outside for both rods.
Tighten the connecting rods nuts evenly to specification with a 10 mm socket.
Connecting Rod Big End Cap Nuts: 34 N-m, 3.5 kgf-m, 25 ft-lb
Inspection
Connecting Rod Big End Side Clearance
Check the side clearance of the big end of the connecting rod with a feeler gauge. Check the clearance on either side between the rod and the crank weight.
Connecting Rod Big End Side Clearance: 0.16 – 0.46 mm (0.0063 – 0.0181 in.)
Service Limit: 0.7 mm (0.028 in.)
Rod Bend and Twist
Remove the connecting rod big end bearing inserts.
Install the big end cap to the rods with out the bearing inserts installed. Place an arbor, with the same diameter as the big end of the connecting rod, through the big end of the connecting rod. In the same fashion place an arbor through the small end of the connecting rod. The arbor on the small end must be greater than 100 mm in length.
Place the large arbor on V-blocks so that the rod is pointing straight up. Use a height gauge to measure the height of the small arbor 50 mm to each side of the center (inline with the nuts) of the connecting rod.
The rod bend is the difference between the measurements. Replace the rod if the difference between the height measurements is greater than 0.2 mm.
Now rotate the rod on the V-blocks so that is pointing to the side at a right angle. Measure the height difference as in the rod bend check. The difference in the new measurements is the rod twist. Replace the rod if the rod twist is greater than 0.2 mm.
Crank-pin-to-Connecting Rod Bearing Insert Clearance
Make sure the connecting rod bearing inserts and the crank-pins are oil free.
Install the connecting rod big end bearing inserts onto the crankshaft with a strip of Plastigauge between the bearing insert and the crank pin. Do not use lubrication or turn the components when using the Plastigauge.
Disassemble the components and inspect the Plastigauge. Measure at the widest section of the Plastigauge for an accurate measurement. Remove the Plastigauge when finished.
Insert/Crankpin Clearance: 0.028 – 0.052 mm (0.0011 – 0.0020 in.)
Service Limit: 0.09 mm (0.0035 in.)
If the clearance is in the specification the connecting rod bearing inserts are the correct size.
If the measurement is above the standard, but below the service limit install the green bearing inserts and recheck the clearance. The clearance must not be below the specification, but it may be above as long as it is below the service limit.
If the clearance is still too great with the green bearing inserts measure the crankpin diameter with a micrometer. Replace the crankshaft if the measurement is below the service limit.
Crankpin Diameter: 39.984 – 40.000 mm (1.5742-1.5748 in.)
Service Limit: 39.97 mm (1.5736 in.)
If the measurement of the crankpin indicates it should have a mark, and it doesn’t place a circular mark on the right crank weight.
Circular Marking
None: 39.984 – 39.992 mm (1.5742 – 1.57449 in.)
‘0’ Mark: 39.993 – 40.000 mm (1.57452-1.5748 in.)
Connecting Rod Bearing Selection
Measure the inside diameter of the big end of the connecting rod with the cap installed, but with out the bearing inserts. Use a micrometer. Mark the side of the connecting rod where the rod and big end cap meet with a circle as needed.
Connecting Rod Big End Inside Diameter: 43.000 – 43.016 mm (1.6929 – 1.6939 in.)
Marking – None: 43.000 – 43.008 mm (1.6929 – 1.69323 in.)
Marking – 0: 43.009 – 43.016 mm (1.69326 – 1.6935 in.)
Select the appropriate bearing inserts for the connecting rods.
| Con-rod Big End Bore Diameter Marking | Crankpin Diameter Marking | Bearing Insert | |
| Size Color | Part Number | ||
| None | O | Brown | 92028-1963 |
| None | None | Yellow | 92028-1962 |
| O | O | ||
| O | None | Green | 92028-1961 |
Crankshaft Runout
Lay the crankshaft on a pair of V blocks and use a dial indicator with a magnetic base to check the amount of crankshaft runout. Measure the runout where the crank journals would fit in their bearings in the crankcase.
Compare your measurement with specification. If the crankshaft runout is not within specification, it will either have to be trued by an OEM dealer or a qualified machine shop or replaced.
Crankshaft Runout (TIR): 0.04 mm
Service Limit: 0.10 mm
Crankshaft Journal and Main Bearing Wear
Measure the outside diameter of the crank journals with a micrometer. Replace the crankshaft if the crank journals are out of specification.
Crankshaft Main Journal Diameter: 41.984 – 42.000 mm (1.6529 – 1.6535 in.)
Service Limit: 41.96 mm (1.652 in.)
Measure the inside diameter of the main bearings with a telescoping gauge. If the crank main bearings show signs of damage or are out of specification the crankcase halves must be replaced.
Crankshaft Main Bearing Bore Diameter: 42.025 – 42.041 mm (1.6545 – 1.6552 in.)
Service Limit: 42.08 mm (1.6567 in.)