Motorcycle engine repair Kawasaki ZX-6R/ZX-600-J (2000-2002)
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Engine top end exploded view
T1: 9.8 N·m (1.0 kg·m, 87 in·lb) T2: 11 Nm (1.1 kg·m, 95 in·lb) T3: 12 Nm (1.2 kg·m, 104 in·lb) T4: 13 N·m (1.3 kg·m, 113 in·lb) T5 15 N·m (1.5 kg·m, 11.0 ft·lb) T6: 25 N·m (2.5 kg·m. 18.0 ft·lb) T7: 20 N·m (2.0 kg·m, 14.5 ft·lb) T8. 49 N·m (5.0...
T1: 9.8 N·m (1.0 kg·m, 87 in·lb) T2: 11 Nm (1.1 kg·m, 95 in·lb) T3: 12 Nm (1.2 kg·m, 104 in·lb) T4: 13 N·m (1.3 kg·m, 113 in·lb) T5 15 N·m (1.5 kg·m, 11.0 ft·lb) T6: 25 N·m (2.5 kg·m. 18.0 ft·lb) T7: 20 N·m (2.0 kg·m, 14.5 ft·lb) T8. 49 N·m (5.0...
Engine top end specifications
ItemStandardService Limit Clean Air System: Vacuum switch valve closing pressure:Open—Close 57-65 kPa (430-490 mmHg)— Camshafts Cam height: Exhaust34.345-34.453 mm34.24 mm Inlet35 146-35.254 mm35.04 mm Camshaft journal, camshaft cap...
ItemStandardService Limit Clean Air System: Vacuum switch valve closing pressure:Open—Close 57-65 kPa (430-490 mmHg)— Camshafts Cam height: Exhaust34.345-34.453 mm34.24 mm Inlet35 146-35.254 mm35.04 mm Camshaft journal, camshaft cap...
Air suction valve — removal and installation
Removal Remove: Seats (see Frame chapter) Fuel Tank, Air Cleaner Housing (see Fuel System chapter) Separate of intake silencer [A] from the vacuum switch valve [B]. Remove: Vacuum Switch Valve with the Hoses Air Suction Valve Cover Bolts [C] Air...
Removal Remove: Seats (see Frame chapter) Fuel Tank, Air Cleaner Housing (see Fuel System chapter) Separate of intake silencer [A] from the vacuum switch valve [B]. Remove: Vacuum Switch Valve with the Hoses Air Suction Valve Cover Bolts [C] Air...
Air suction valve — inspection
Visually inspect the reeds [A] for cracks, folds, warps, heat damage, or other damage. ★ If there is any doubt as to the condition of the reed, replace the air suction valve as an assembly. Check the reed contact areas [B] of the valve holder for...
Visually inspect the reeds [A] for cracks, folds, warps, heat damage, or other damage. ★ If there is any doubt as to the condition of the reed, replace the air suction valve as an assembly. Check the reed contact areas [B] of the valve holder for...
Vacuum switch valve — removal and installation
Removal Remove the vacuum switch valve (see Air Suction Valve Removal this chapter). Installation Install the vacuum switch valve so that the air hole [A] faces downwards. Route the hoses correctly (see General Information chapter).
Removal Remove the vacuum switch valve (see Air Suction Valve Removal this chapter). Installation Install the vacuum switch valve so that the air hole [A] faces downwards. Route the hoses correctly (see General Information chapter).
Vacuum switch valve — test
Remove: Fuel Tank, Air Cleaner Housing (see Fuel System chapter) Vacuum Switch Valve Connect a vacuum gauge [A] and syringe [B] or fork oil level gauge to the vacuum hoses as shown. Special Tool - Fork Oil Level Gauge: 57001-1290 Air Flow [C]....
Remove: Fuel Tank, Air Cleaner Housing (see Fuel System chapter) Vacuum Switch Valve Connect a vacuum gauge [A] and syringe [B] or fork oil level gauge to the vacuum hoses as shown. Special Tool - Fork Oil Level Gauge: 57001-1290 Air Flow [C]....
Clean air system hose — inspection
Be certain that all the hoses are routed without being flattened or kinked, and are connected correctly to the air cleaner housing, vacuum switch valve, #1 and #4 carburetor holders and air suction valve covers. ★ If they are not, correct them....
Be certain that all the hoses are routed without being flattened or kinked, and are connected correctly to the air cleaner housing, vacuum switch valve, #1 and #4 carburetor holders and air suction valve covers. ★ If they are not, correct them....
Cylinder head cover — removal
Remove: Lower Fairing (see Frame chapter) Coolant (drain, see Cooling System chapter) Other than US, CA Models Fuel Tank, Air Cleaner Housing and Carburetor (see Fuel System chapter) Seats (see Frame chapter) Vacuum Valve (California Model only)...
Remove: Lower Fairing (see Frame chapter) Coolant (drain, see Cooling System chapter) Other than US, CA Models Fuel Tank, Air Cleaner Housing and Carburetor (see Fuel System chapter) Seats (see Frame chapter) Vacuum Valve (California Model only)...
Cylinder head cover — installation
Replace the head cover gasket with a new one if damaged. Apply silicone sealant to the cylinder head as shown [A]. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 Be sure to install the pins [A] and rubber gaskets [B]. Install the washer with...
Replace the head cover gasket with a new one if damaged. Apply silicone sealant to the cylinder head as shown [A]. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 Be sure to install the pins [A] and rubber gaskets [B]. Install the washer with...
Camshaft chain tensioner — removal
Caution! This is a non-return type camshaft chain tensioner. The push rod does not return to its original position once it moves out to take up camshaft chain slack. Observe all the rules listed below: When removing the tensioner, do not take out...
Caution! This is a non-return type camshaft chain tensioner. The push rod does not return to its original position once it moves out to take up camshaft chain slack. Observe all the rules listed below: When removing the tensioner, do not take out...
Camshaft chain tensioner — installation
Release the stopper [A] and push the push rod [B] into the tensioner body [C]. Insert the push rod so that the push rod teeth are leaved five notches. Install the tensioner body so that the stopper faces upward. Tighten the tensioner mounting bolts...
Release the stopper [A] and push the push rod [B] into the tensioner body [C]. Insert the push rod so that the push rod teeth are leaved five notches. Install the tensioner body so that the stopper faces upward. Tighten the tensioner mounting bolts...
Camshaft — removal
Remove: Cylinder Head Cover (see Cylinder Head Cover Removal) Pickup Coil Cover Position the crankshaft at #1, 4 piston TDC. [A] TDC mark for #1, 4 pistons [B] Timing Mark (crankcase halves mating surface) Remove: Camshaft Chain Tensioner (see...
Remove: Cylinder Head Cover (see Cylinder Head Cover Removal) Pickup Coil Cover Position the crankshaft at #1, 4 piston TDC. [A] TDC mark for #1, 4 pistons [B] Timing Mark (crankcase halves mating surface) Remove: Camshaft Chain Tensioner (see...
Camshaft — installation
Be sure to install the following parts. [A] O-rings [B] Pins Apply engine oil to all cam parts and journals. If a new camshaft is to be used, apply a thin coat of molybdenum disulfide grease to the cam surfaces. Note. The exhaust camshaft has a 117...
Be sure to install the following parts. [A] O-rings [B] Pins Apply engine oil to all cam parts and journals. If a new camshaft is to be used, apply a thin coat of molybdenum disulfide grease to the cam surfaces. Note. The exhaust camshaft has a 117...
Camshaft, camshaft cap wear
Cut strips of plastigage to journal width. Place a strip on each journal parallel to the camshaft installed in the correct position. Measure each clearance between the camshaft journal and the camshaft cap using plastigage (press gauge) [A]....
Cut strips of plastigage to journal width. Place a strip on each journal parallel to the camshaft installed in the correct position. Measure each clearance between the camshaft journal and the camshaft cap using plastigage (press gauge) [A]....
Camshaft chain removal and wear
Removal Split the crankcase (see Crankshaft chapter). Remove the camshaft chain [A] from the crankshaft sprocket. Wear Hold the chain taut with a force of about 49 N (5 kg, 11 lb) in some manner, and measure a 20-link length. Since the chain may...
Removal Split the crankcase (see Crankshaft chapter). Remove the camshaft chain [A] from the crankshaft sprocket. Wear Hold the chain taut with a force of about 49 N (5 kg, 11 lb) in some manner, and measure a 20-link length. Since the chain may...
Cylinder compression measurement
Note. Use the battery which is fully charged. Warm up the engine thoroughly. Stop the engine. Remove: Seats (see Frame chapter) Fuel Tank (see Fuel System chapter) Air Cleaner Housing (see Fuel System chapter) Stick Coils Spark Plugs Special Tool -...
Note. Use the battery which is fully charged. Warm up the engine thoroughly. Stop the engine. Remove: Seats (see Frame chapter) Fuel Tank (see Fuel System chapter) Air Cleaner Housing (see Fuel System chapter) Stick Coils Spark Plugs Special Tool -...
Cylinder head — removal
Drain the coolant (see Cooling System chapter). Remove: Cylinder Head Cover (see Cylinder Head Cover Removal) Camshaft Chain Tensioner (see Camshaft Chain Tensioner Removal) Camshafts (see Camshaft Removal) Water Temperature Sensor Lead Connector...
Drain the coolant (see Cooling System chapter). Remove: Cylinder Head Cover (see Cylinder Head Cover Removal) Camshaft Chain Tensioner (see Camshaft Chain Tensioner Removal) Camshafts (see Camshaft Removal) Water Temperature Sensor Lead Connector...
Cylinder head — installation
Note. The camshaft cap is machined with the cylinder head, so ft a new cylinder head is installed, use the cap that is supplied with the new head. Install a new cylinder head gasket and knock pins. Apply engine oil to both sides [A] of the cylinder...
Note. The camshaft cap is machined with the cylinder head, so ft a new cylinder head is installed, use the cap that is supplied with the new head. Install a new cylinder head gasket and knock pins. Apply engine oil to both sides [A] of the cylinder...
Cylinder head warp
Lay a straightedge across the lower surface of the cylinder head at several positions. Use a thickness gauge [A] to measure the space between the straightedge [B] and the head. Cylinder Head Warp Standard: — Service Limit: 0.05 mm ★ If the cylinder...
Lay a straightedge across the lower surface of the cylinder head at several positions. Use a thickness gauge [A] to measure the space between the straightedge [B] and the head. Cylinder Head Warp Standard: — Service Limit: 0.05 mm ★ If the cylinder...
Valve clearance — inspection
Note. Valve clearance must be checked and adjusted when the engine is cold (at room temperature). Remove: Lower Fairings (see Frame chapter) Pickup Coil Cover Cylinder Head Cover (see Cylinder Head Cover Removal) Position the crankshaft at 1, 4...
Note. Valve clearance must be checked and adjusted when the engine is cold (at room temperature). Remove: Lower Fairings (see Frame chapter) Pickup Coil Cover Cylinder Head Cover (see Cylinder Head Cover Removal) Position the crankshaft at 1, 4...
Valve clearance — adjustment
To change the valve clearance, remove the camshaft chain tensioner, camshafts and valve lifters. Replace the shim with one of a different thickness. Note. Mark and record the valve lifter and shim locations so they can be reinstalled in their...
To change the valve clearance, remove the camshaft chain tensioner, camshafts and valve lifters. Replace the shim with one of a different thickness. Note. Mark and record the valve lifter and shim locations so they can be reinstalled in their...
Valve — removal and installation
Removal Remove the cylinder head (see Cylinder Head Removal). Remove the valve lifter and shim. Mark and record the valve lifter and shim locations so they can be installed in their original positions. Using the valve spring compressor assembly,...
Removal Remove the cylinder head (see Cylinder Head Removal). Remove the valve lifter and shim. Mark and record the valve lifter and shim locations so they can be installed in their original positions. Using the valve spring compressor assembly,...
Valve guide — removal and installation
Removal Remove: Valve (see Valve Removal) Oil Seal Spring Seat Heat the area around the valve guide to 120-150°C (248-302°F), and hammer lightly on the valve guide arbor [A] to remove the guide from the top of the head. Caution! Do not heat the...
Removal Remove: Valve (see Valve Removal) Oil Seal Spring Seat Heat the area around the valve guide to 120-150°C (248-302°F), and hammer lightly on the valve guide arbor [A] to remove the guide from the top of the head. Caution! Do not heat the...
Valve-to-guide clearance measurement (wobble method)
If a small bore gauge is not available, inspect the valve guide wear by measuring the valve to valve guide clearance with the wobble method as indicated below. Insert a new valve [A] into the guide [B] and set a dial gauge against the stem...
If a small bore gauge is not available, inspect the valve guide wear by measuring the valve to valve guide clearance with the wobble method as indicated below. Insert a new valve [A] into the guide [B] and set a dial gauge against the stem...
Valve seat — inspection
Remove the valve (see Valve Removal). Check the valve seating surface [A] between the valve [B] and valve seat [C]. Measure the outside diameter [D] of the seating pattern on the valve seat. ★ If the outside diameter is too large or too small,...
Remove the valve (see Valve Removal). Check the valve seating surface [A] between the valve [B] and valve seat [C]. Measure the outside diameter [D] of the seating pattern on the valve seat. ★ If the outside diameter is too large or too small,...
Valve seat — repair
Repair the valve seat with the valve seat cutters [A]. Special Tool: Valve Seat Cutter Holder, 04: 57001-1275 [B] Valve Seat Cutter Holder Bar: 57001-1128 [C] [For Inlet Valve Seat] Valve Seat Cutter, 45° - ∅24: 57001-1113 Valve Seat Cutter, 32° -...
Repair the valve seat with the valve seat cutters [A]. Special Tool: Valve Seat Cutter Holder, 04: 57001-1275 [B] Valve Seat Cutter Holder Bar: 57001-1128 [C] [For Inlet Valve Seat] Valve Seat Cutter, 45° - ∅24: 57001-1113 Valve Seat Cutter, 32° -...
Cylinder — removal and installation
Removal Remove: Engine (see Engine Removal/lnstallation chapter) Cylinder Head (see Cylinder Head Removal) Water Hoses [A] Rear Camshaft Chain Guide and Bolt Remove the cylinder. Installation Note. If a new cylinder is used, use new piston ring....
Removal Remove: Engine (see Engine Removal/lnstallation chapter) Cylinder Head (see Cylinder Head Removal) Water Hoses [A] Rear Camshaft Chain Guide and Bolt Remove the cylinder. Installation Note. If a new cylinder is used, use new piston ring....
Piston — removal and installation
Removal Remove the cylinder (see Cylinder Removal). Place a clean cloth under the pistons and remove the piston pin snap ring [A] from the outside of each piston. Remove the piston pins. Special Tool - Piston Pin Puller Assembly: 57001-910 [A]...
Removal Remove the cylinder (see Cylinder Removal). Place a clean cloth under the pistons and remove the piston pin snap ring [A] from the outside of each piston. Remove the piston pins. Special Tool - Piston Pin Puller Assembly: 57001-910 [A]...
Cylinder wear
Since there is a difference in cylinder wear in different directions, take a side-to-side and a front-to-back measurement at each of the two locations (total of four measurements) shown in the figure. If any of the cylinder inside diameter...
Since there is a difference in cylinder wear in different directions, take a side-to-side and a front-to-back measurement at each of the two locations (total of four measurements) shown in the figure. If any of the cylinder inside diameter...
Piston wear
Measure the outside diameter [A] of each piston 5 mm [B] up from the bottom of the piston at a right angle to the direction of the piston pin. ★ If the measurement is under service limit, replace the piston. Piston Diameter Standard: 65.935-65.950...
Measure the outside diameter [A] of each piston 5 mm [B] up from the bottom of the piston at a right angle to the direction of the piston pin. ★ If the measurement is under service limit, replace the piston. Piston Diameter Standard: 65.935-65.950...
Piston ring groove wear
Check for uneven groove wear by inspecting the ring seating. ★ The rings should fit perfectly parallel to groove surfaces. If not, replace the piston and all the piston rings. With the piston rings in their grooves, make several measurements with a...
Check for uneven groove wear by inspecting the ring seating. ★ The rings should fit perfectly parallel to groove surfaces. If not, replace the piston and all the piston rings. With the piston rings in their grooves, make several measurements with a...
Piston ping groove width
Measure the piston ring groove width. Use a vernier caliper at several points around the piston. Piston ring/groove width StandardService Limit Top0.84-0.86 mm0.94 mm Second0.82-0.84 mm0.92 mm ★ If the width of any of the two grooves is wider than...
Measure the piston ring groove width. Use a vernier caliper at several points around the piston. Piston ring/groove width StandardService Limit Top0.84-0.86 mm0.94 mm Second0.82-0.84 mm0.92 mm ★ If the width of any of the two grooves is wider than...
Piston ping thickness
Measure the piston ring thickness. Use the micrometer to measure at several points around the ring. Piston ring thickness StandardService Limit Top0.77-0.79 mm0.70 mm Second0.77-0.79 mm0.70 mm ★ If any of the measurements is less than the service...
Measure the piston ring thickness. Use the micrometer to measure at several points around the ring. Piston ring thickness StandardService Limit Top0.77-0.79 mm0.70 mm Second0.77-0.79 mm0.70 mm ★ If any of the measurements is less than the service...
Piston ring end gap
Place the piston ring [A] inside the cylinder, using the piston to locate the ring squarely in place. Set it close to the bottom of the cylinder, where cylinder wear is low. Measure the gap [B] between the ends of the ring with a thickness gauge....
Place the piston ring [A] inside the cylinder, using the piston to locate the ring squarely in place. Set it close to the bottom of the cylinder, where cylinder wear is low. Measure the gap [B] between the ends of the ring with a thickness gauge....
Carburetor holder installation
Be sure to install the O-ring [A]. Tighten the carburetor holder bolts [B]. Tighten the #1,3 right carburetor holder bolts with clamp [C] (use of clamps for California Model only). Torque - Carburetor Holder Bolts: 12 N·m (1.2 kg·m, 104 in·lb)
Be sure to install the O-ring [A]. Tighten the carburetor holder bolts [B]. Tighten the #1,3 right carburetor holder bolts with clamp [C] (use of clamps for California Model only). Torque - Carburetor Holder Bolts: 12 N·m (1.2 kg·m, 104 in·lb)
Muffler and exhaust pipe — removal and installation
Pemoval Warning! To avoid a serious burn, do not remove the mufflers when the engine is still hot. Wait until the mufflers cool down. Remove: Lower Fairings (see Frame chapter) Exhaust Pipe Mounting Bolt [A] Remove the muffler mounting nut [A]....
Pemoval Warning! To avoid a serious burn, do not remove the mufflers when the engine is still hot. Wait until the mufflers cool down. Remove: Lower Fairings (see Frame chapter) Exhaust Pipe Mounting Bolt [A] Remove the muffler mounting nut [A]....
Muffler body — removal and installation
Removal Remove: Exhaust Pipe Connecting Nuts [A] Muffler Mounting Bolt, Nut [B] and Washer Pull the muffler body [C] backward Installation Replacing the muffler body gasket with new one. Tighten: Torque - Muffler Body and Exhaust Pipe Connecting...
Removal Remove: Exhaust Pipe Connecting Nuts [A] Muffler Mounting Bolt, Nut [B] and Washer Pull the muffler body [C] backward Installation Replacing the muffler body gasket with new one. Tighten: Torque - Muffler Body and Exhaust Pipe Connecting...
Engine removal and installation
T1: 44 N·m (4.5 kg·m, 33 ft·lb) T2: 25 N·m (2.5 kg·m, 18 ft·lb) T3: 49 N·m (5.0 kg·m, 36 ft·lb) Specifications Special Tool: Jack: 57001-1238 Engine Mount Nut Wrench: 57001-1450
T1: 44 N·m (4.5 kg·m, 33 ft·lb) T2: 25 N·m (2.5 kg·m, 18 ft·lb) T3: 49 N·m (5.0 kg·m, 36 ft·lb) Specifications Special Tool: Jack: 57001-1238 Engine Mount Nut Wrench: 57001-1450
Engine — removal
Squeeze the brake lever slowly and hold it with a band [A]. Warning! Be sure to hold the front brake when removing the engine, or the motorcycle may fall over. It could cause an accident and injury. Caution! Be sure to hold the front brake when...
Squeeze the brake lever slowly and hold it with a band [A]. Warning! Be sure to hold the front brake when removing the engine, or the motorcycle may fall over. It could cause an accident and injury. Caution! Be sure to hold the front brake when...
Engine — installation
Before engine installation loosen the engine bracket bolts [A]. Support the engine with a suitable stand. Hang the drive chain over the output shaft just before moving the engine into its final position in the frame. Screw the adjusting bolts [H],...
Before engine installation loosen the engine bracket bolts [A]. Support the engine with a suitable stand. Hang the drive chain over the output shaft just before moving the engine into its final position in the frame. Screw the adjusting bolts [H],...
Crankshaft and transmission exploded view
T1: 5.4 N·m (0.55 kg·m, 48 in·lb) T2: 9.8 N·m (1.0 kg·m, 87 in·lb) T3: 12 N·m (1.2 kg·m. 104 in·lb) T4: 15 N·m (1.5 kg·m, 11.0 ft·lb) T5: 20 N·m (2.0 kg·m, 14.5 ft·lb) T6: 28 N·m (2.9 kg·m, 21 ft·lb) T7: 40 N·m (4.0 kg·m, 29 ft·lb) T8: 30 N·m (3.0...
T1: 5.4 N·m (0.55 kg·m, 48 in·lb) T2: 9.8 N·m (1.0 kg·m, 87 in·lb) T3: 12 N·m (1.2 kg·m. 104 in·lb) T4: 15 N·m (1.5 kg·m, 11.0 ft·lb) T5: 20 N·m (2.0 kg·m, 14.5 ft·lb) T6: 28 N·m (2.9 kg·m, 21 ft·lb) T7: 40 N·m (4.0 kg·m, 29 ft·lb) T8: 30 N·m (3.0...
Crankshaft and transmission exploded specifications
ItemStandardService Limit Crankshaft, Connecting Rods: Connecting rod big end side clearance0.13-0.33 mm0.5 mm Connecting rod big end bearing inserVcrankpin clearance0.031-0.059 mm0.10 mm Crankpin diameter:29.984-30.000 mm29.97 mm Marking:...
ItemStandardService Limit Crankshaft, Connecting Rods: Connecting rod big end side clearance0.13-0.33 mm0.5 mm Connecting rod big end bearing inserVcrankpin clearance0.031-0.059 mm0.10 mm Crankpin diameter:29.984-30.000 mm29.97 mm Marking:...
Crankcase — splitting
Remove the engine (see Engine Removal/lnstallation chapter). Set the engine on a clean surface and hold the engine steady while parts are being removed. Remove: Pickup Coil (see Electrical System chapter) Oil Hose (Cylinder Head - Lower Crankcase)...
Remove the engine (see Engine Removal/lnstallation chapter). Set the engine on a clean surface and hold the engine steady while parts are being removed. Remove: Pickup Coil (see Electrical System chapter) Oil Hose (Cylinder Head - Lower Crankcase)...
Crankcase — assembly
Caution! The upper and lower crankcase halves are machined at the factory in the assembled state, so the crankcase halves must be replaced as a set. With a high-flash point solvent, clean off the mating surfaces of the crankcases halves and wipe...
Caution! The upper and lower crankcase halves are machined at the factory in the assembled state, so the crankcase halves must be replaced as a set. With a high-flash point solvent, clean off the mating surfaces of the crankcases halves and wipe...
Crankshaft — removal and installation
Removal Split the crankcase (see Crankcase Splitting). Remove the crankshaft. Installation Caution! If the crankshaft, bearing inserts, or crankcase halves are replaced with new ones, select the bearing inserts and check clearance with a plastigage...
Removal Split the crankcase (see Crankcase Splitting). Remove the crankshaft. Installation Caution! If the crankshaft, bearing inserts, or crankcase halves are replaced with new ones, select the bearing inserts and check clearance with a plastigage...
Connecting rod — removal and installation
Removal Split the crankcase (see Crankcase Splitting). Remove the connecting rod nuts. Remove the crankshaft. Note. Mark and record the locations of the connecting rods and their big end caps so that they can be reassembled in their original...
Removal Split the crankcase (see Crankcase Splitting). Remove the connecting rod nuts. Remove the crankshaft. Note. Mark and record the locations of the connecting rods and their big end caps so that they can be reassembled in their original...
Connecting rod big end side clearance
Measure connecting rod big end side clearance [A]. Insert a thickness gauge [B] between the big end and either crank web to determine clearance. Connecting rod big end side clearance Standard: 0.13-0.33 mm Service Limit: 0.5 mm ★ If the clearance...
Measure connecting rod big end side clearance [A]. Insert a thickness gauge [B] between the big end and either crank web to determine clearance. Connecting rod big end side clearance Standard: 0.13-0.33 mm Service Limit: 0.5 mm ★ If the clearance...
Connecting rod big end bearing insert/crankpin wear
Using a plastigage (press gauge) [A], measure the bearing insert/ crankpin [B] clearance. Note. Tighten the connecting rod big end nuts to the specified torque (see Connecting Rod Installation). Do not move the connecting rod and crankshaft during...
Using a plastigage (press gauge) [A], measure the bearing insert/ crankpin [B] clearance. Note. Tighten the connecting rod big end nuts to the specified torque (see Connecting Rod Installation). Do not move the connecting rod and crankshaft during...
Crankshaft main bearing insert/journal wear
Using a plastigage (press gauge) [A], measure the bearing insert/ journal [B] clearance. Note. Tighten the crankcase bolts to the specified torque (see Crankcase Assembly). Do not turn the crankshaft during clearance measurement. Journal clearance...
Using a plastigage (press gauge) [A], measure the bearing insert/ journal [B] clearance. Note. Tighten the crankcase bolts to the specified torque (see Crankcase Assembly). Do not turn the crankshaft during clearance measurement. Journal clearance...
Crankshaft side clearance
Insert a thickness gauge [A] between the crankcase main bearing and the crank web at the No.2 journal [B] to determine clearance. If the clearance exceeds the service limit replace the crankcase halves as a set. Caution! The upper and lower...
Insert a thickness gauge [A] between the crankcase main bearing and the crank web at the No.2 journal [B] to determine clearance. If the clearance exceeds the service limit replace the crankcase halves as a set. Caution! The upper and lower...
Crankshaft runout
Measure the crankshaft runout. ★ If the measurement exceeds the service limit, replace the crankshaft. Crankshaft runout Standard: TIR 0.02 mm or less Service Limit: TIR 0.05 mmm
Measure the crankshaft runout. ★ If the measurement exceeds the service limit, replace the crankshaft. Crankshaft runout Standard: TIR 0.02 mm or less Service Limit: TIR 0.05 mmm
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