| Item | Standard | Service Limit |
| Crankshaft, Connecting Rods: | ||
| Connecting rod big end side clearance | 0.13-0.33 mm | 0.5 mm |
| Connecting rod big end bearing inserVcrankpin clearance | 0.031-0.059 mm | 0.10 mm |
| Crankpin diameter: | 29.984-30.000 mm | 29.97 mm |
| Marking: None | 29.984-29.994 mm | — |
| Marking: O | 29.995-30.000 mm | — |
| Connecting rod big end bore diameter: | 33.000-33.016 mm | — |
| Marking: None | 33.000-33.008 mm | — |
| Marking: O | 33.009 -- 33.016 mm | — |
| Connecting rod big end bearing insert thickness: | ||
| Brown | 1.475-1.480 mm | — |
| Colorless | 1.480-1.485 mm | — |
| Blue | 1.485-1.490 mm | — |
Connecting rod big end bearing insert selection:
| Con-rod Big End Bore Diameter Marking | Crankpin Diameter Marking | Bearing Insert | |
| Size Color | Part Number | ||
| None | O | Pink | 92028-1880 |
| None | None | Brown | 92028-1879 |
| O | O | ||
| O | None | Black | 92028-1878 |
| Crankshaft side clearance | 0.05-0.20 mm | 0.40 mm |
| Crankshaft runout | TIR 0.02 mm or less | TIR 0.05 mm |
| Crankshaft main bearing insert/ | ||
| journal clearance | 0.014-0.038 mm | 0.07 mm |
| Crankshaft main journal diameter: | 29.984-30.000 mm | 29.96 mm |
| Marking: None | 29.984-29.994 mm | — |
| Marking: 1 | 29.995-30.000 mm | — |
| Crankcase main bearing bore diameter: | 33.000-33.016 mm | — |
| Marking: O | 33.000-33.008 mm | — |
| Marking: None | 33.009-33.016 mm | — |
| Crankshaft main bearing insert thickness: | ||
| Brown | 1.491-1.495 mm | — |
| Black | 1.49 1.499 mm | — |
| Blue | 1.499-1.503 mm | — |
Crankshaft main bearing insert selection:
| Crankcase Main Bearing Bore Diameter Marking | Crankshaft Main Journal Diameter Marking | Bearing Insert* | ||
| Size Color | Part Number | Journal Nos. | ||
| O | 1 | Brown | 92028-1883 | 3, 5 |
| 92028-1886 | 1, 2, 4 | |||
| None | 1 | Black | 92028-1882 | 3, 5 |
| O | None | 92028-1885 | 1, 2, 4 | |
| None | None | Blue | 92028-1881 | 3, 5 |
| 92028-1884 | 1, 2, 4 | |||
The bearing inserts for Nos. 1, 2 and 4 journals have an oil groove, respectively.
| Item | Standard | Service Limit |
| Transmission: | ||
| Shift fork ear thickness | 5.9-6.0 mm | 5.8 mm |
| Gear groove width | 6.05-6.15 mm | 6.25 mm |
| Shift fork guide pin diameter | 5.9-6.0 mm | 5.8 mm |
| Shift drum groove width | 6.05-6.20 mm | 6.3 mm |
Special Tool:
- Outside Circlip Pliers: 57001-144
- Bearing Puller: 57001-135
- Flywheel & Pulley Holder: 57001-1343
- Bearing Puller Adapter: 57001-317
Sealant:
- Kawasaki Bond (Silicone Sealant): 56019-120
- Kawasaki Bond (Silicone Sealant): 92104-1063