| Item | Standard | Service Limit |
| Clean Air System: | ||
| Vacuum switch valve closing pressure: | Open—Close | |
| 57-65 kPa (430-490 mmHg) | — | |
| Camshafts | ||
| Cam height: Exhaust | 34.345-34.453 mm | 34.24 mm |
| Inlet | 35 146-35.254 mm | 35.04 mm |
| Camshaft journal, camshaft cap clearance | 0.038-0.081 mm | 0.17 mm |
| Camshaft journal diameter | 23.940-23.962 mm | 23.91 mm |
| Camshaft bearing inside diameter | 24.000-24.021 mm | 24.08 mm |
| Camshaft runout | TIR 0.02 mm or less | TIR 0.1 mm |
| Camshaft chain 20-link length | 127.00-127.36 mm | 128.9 mm |
| Cylinder Head: | ||
| Cylinder compression | (usable range) | |
| 950-1450 kPa | — | |
| (9.7-14.8 kg/cm2, 138-210 psi) | ||
| @350 r/min (rpm) | ||
| Cylinder head warp | — | 0.05 mm |
| Valves: | ||
| Valve clearance: Exhaust | 0.22-0.31 mm | — |
| Inlet | 0.11-0.19 mm | — |
| Valve head thickness: Exhaust | 1.0 mm | 0.6 mm |
| Inlet | 0.5 mm | 0.25 mm |
| Valve stem bend | TIR 0.01mm or less | TIR 0.05 mm |
| Valve stem diameter: Exhaust | 3.955-3.970 mm | 3.94 mm |
| Inlet | 3.975-3.990 mm | 3.96 mm |
| Valve guide inside diameter: Exhaust | 4.000-4.012 mm | 4.08 mm |
| Inlet | 4.000-4.012 mm | 4.08 mm |
| Valve/valve guide clearance | ||
| (wobble method): Exhaust | 0.10-0.18 mm | 0.35 mm |
| Inlet | 0.03 -0.12 mm | 0.29 mm |
| Valve seat cutting angle | 45°, 32,60 | — |
| Valve seat surface: | ||
| Width: Exhaust | 0.5-1.0 mm | — |
| Inlet | 0.5-1.0 mm | — |
| Outside diameter: Exhaust | 22.1-22.3 mm | — |
| Inlet | 26.1-26.3 mm | |
| Valve spring free length: Exhaust (Inner) | 49.0 mm | 47.6 mm |
| Inlet (Inner) | 44.1 mm | 42.6 mm |
| Inlet (Outer) | 48.2 mm | 46.6 mm |
| Cylinder, Piston: | ||
| Cylinder inside diameter | 65.960-65.972 mm | 66.06 mm |
| Piston diameter | 65.935-65.950 mm | 65.78 mm |
| Piston/cylinder clearance: | 0.010-0.037 mm | — |
| Piston ring/groove clearance Top | 0.05-0.09 mm | 0.19 mm |
| Second | 0.03-0.07 mm | 0.17 mm |
| Piston ring groove width: Top | 0.84-0.86 mm | 0.94 mm |
| Second | 0.82-0.84 mm | 0.92 mm |
| Piston ring thickness: Top | 0.77-0.79 mm | 0.70 mm |
| Second | 0.77-0.79 mm | 0.70 mm |
| Piston ring end gap: Top | 0.15-0.30 mm | 0.6 mm |
| Second | 0.30-0.45 mm | 0.8 mm |
Special Tools:
- Fork Oil Level Gauge: 57001-1290
- Compression Gauge: 57001-221
- Compression Gauge Adapter, M10x1.0: 57001-1317
- Valve Spring Compressor Assembly: 57001-241
- Valve Spring Compressor Adapter, ∅22: 57001-1202
- Valve Guide Arbor, ∅4.5: 57001-1331
- Valve Guide Reamer, ∅4.5: 57001-1333
- Valve Seat Cutter, 45° - ∅32: 57001-1115
- Valve Seat Cutter, 32° - ∅30: 57001-1120
- Valve Seat Cutter, 60° - ∅30: 57001-1123
- Valve Seat Cutter, 45° - ∅27.5: 57001-1114
- Valve Seat Cutter, 32'° - ∅28; 57001-1119
- Valve Seat Cutter, 60° - ∅33: 57001-1334
- Valve Seat Cutter Holder, ∅4.5: 57001-1330
- Valve Seat Cutter Holder Bar: 57001-1128
- Piston Pin Puller Assembly: 57001-910
Sealant - Kawasaki Bond (Silicone Sealant): 56019-120