9-6 CRANKSHAFT/TRANSMISSION

Specifications

Item			Standard				Service Limit
Crankcase, 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	0.13	0.38 mm (0.0051		0.0150 in.)			0.58 mm
Clearance							(0.023 in.)
	0.044		0.081 mm (0.0017
Connecting Rod Big End Bearing					0.0032 in.)		0.11 mm
Insert/Crankpin Clearance							(0.0043 in.)
Crankpin Diameter:	29.987		30.000 mm (1.1806			1.1811 in.)	29.98 mm
							(1.1803 in.)
Marking:
None	29.984		29.992 mm (1.1805			1.1808 in.)	– – –
○	29.993		30.000 mm (1.1808			1.1811 in.)	– – –
Connecting Rod Big End Inside	33.000		33.016 mm (1.2992			1.2998 in.)	– – –
Diameter:
Marking:
None	33.000		33.008 mm (1.2992			1.2995 in.)	– – –
○	33.009		33.016 mm (1.2996			1.2998 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 Bolt Stretch	(Usable Range)
	0.28	0.38 mm (0.0110		0.0150 in.)			– – –
Crankshaft Side Clearance	0.05	0.25 mm (0.0020		0.0098 in.)			0.45 mm
							(0.0177 in.)
Crankshaft #3 Main Journal Width	21.09		21.14 mm (0.8303		0.8323 in.)		– – –
Crankshaft Runout	TIR 0.02 mm (0.0008 in.) or less						TIR 0.05 mm
							(0.0020 in.)
	0.028		0.060 mm (0.0011
Crankshaft Main Bearing					0.0024 in.)		0.09 mm
Insert/Journal Clearance							(0.0035 in.)
Crankshaft Main Journal Diameter:	30.984		31.000 mm (1.2198			1.2205 in.)	30.96 mm
							(1.2189 in.)
Marking:
None	30.984		30.992 mm (1.2198			1.2202 in.)	– – –
1	30.993		31.000 mm (1.2202			1.2205 in.)	– – –
Crankcase Main Bearing Inside	34.000		34.016 mm (1.3386			1.3392 in.)	– – –
Diameter:
Marking
○	34.000		34.008 mm (1.3386			1.3389 in.)	– – –
None	34.009		34.016 mm (1.3389			1.3392 in.)	– – –

CRANKSHAFT/TRANSMISSION 9-7

Specifications

Item				Standard					Service Limit
Crankshaft Main Bearing Insert
Thickness:
Brown, Yellow	1.491			1.495 mm (0.0587		0.0589 in.)			– – –
Black, Green	1.495			1.499 mm (0.0589		0.0590 in.)			– – –
Blue, Purple	1.499			1.503 mm (0.0590		0.0592 in.)			– – –
Cylinder , Pistons
Cylinder (Upper Crankcase) Inside	67.000			67.012 mm (2.6378			2.6383 in.)		67.09 mm
Diameter									(2.6413 in.)
Piston Diameter	66.960			66.975 mm (2.6362			2.6368 in.)		66.81 mm
									(2.6303 in.)
Piston/Cylinder Clearance	0.020			0.047 mm (0.0008		0.0019 in.)			– – –
Piston Ring/Groove Clearance:
Top	0.03		0.07 mm (0.0012		0.0028 in.)				0.17 mm
									(0.0067 in.)
Second	0.03		0.07 mm (0.0012		0.0028 in.)				0.17 mm
									(0.0067 in.)
Piston Ring Groove Width:
Top	0.82		0.84 mm (0.0323		0.0331 in.)				0.92 mm
									(0.036 in.)
Second	0.82		0.84 mm (0.0323		0.0331 in.)				0.92 mm
									(0.036 in.)
Piston Ring Thickness:
Top	0.77		0.79 mm (0.0303		0.0311 in.)				0.70 mm
									(0.028 in.)
Second	0.77		0.79 mm (0.0303		0.0311 in.)				0.70 mm
									(0.028 in.)
Piston Ring End Gap:
Top	0.12		0.22 mm (0.0047		0.0087 in.)				0.5 mm
									(0.020 in.)
Second	0.30		0.45 mm (0.0118		0.0177 in.)				0.8 mm
									(0.031 in.)
Oil	0.20		0.70 mm (0.0079		0.0276 in.)				1.0 mm
									(0.039 in.)
Transmission
Shift Fork Ear Thickness	5.9	6.0 mm (0.232 0.236 in.)							5.8 mm
									(0.228 in.)
Gear Groove Width	6.05		6.15 mm (0.238		0.242 in.)				6.25 mm
									(0.246 in.)
Shift Fork Guide Pin Diameter	5.9	6.0 mm (0.232 0.236 in.)							5.8 mm
									(0.228 in.)
Shift Drum Groove Width	6.05		6.20 mm (0.238		0.244 in.)				6.3 mm
									(0.248 in.)

9-8 CRANKSHAFT/TRANSMISSION

Specifications

Connecting Rod Big End Bearing Insert Selection

Con-rod Big End			Crankpin Diameter					Bearing Insert
Inside Diameter
			Marking				Size Color			Part Number
Marking
None			○				Brown			92139-0167
None			None				Black			92139-0166
○			○
○			None					Blue		92139-0165
Crankshaft Main Bearing Insert Selection
Crankcase Main		Crankshaft Main						Bearing Insert*
Bearing Inside	Journal Diameter
					Size Color			Part Number		Journal Nos.
Diameter Marking			Marking
○					Brown			92139-0247		1, 5
			1					92139-0250		2, 4
					Yellow			92139-0253		3
					Black			92139-0246		1, 5
None			1					92139-0249		2, 4
					Green			92139-0252		3
○					Black			92139-0246		1, 5
			None					92139-0249		2, 4
					Green			92139-0252		3
					Blue			92139-0245		1, 5
None			None					92139-0248		2, 4
					Purple			92139-0251		3

*: The bearing inserts for Nos. 2 and 4 journals have an oil groove, respectively.

	CRANKSHAFT/TRANSMISSION 9-9
Special Tools and Sealants
Outside Circlip Pliers:		Grip:
57001-144	57001-1591

Piston Pin Puller Assembly: 57001-910

Rotor Holder: 57001-1666

Piston Ring Compressor Grip:		Stopper:
57001-1095	57001-1679

Piston Ring Compressor Belt, 67 79:

57001-1097

Rotor Holder Attachment: 57001-1689

Bearing Driver Set:		Kawasaki Bond (Silicone Sealant):
57001-1129	92104-0004

9-10 CRANKSHAFT/TRANSMISSION

Special Tools and Sealants

Kawasaki Bond (Liquid Gasket - Black): 92104-1064