Service Information

GENERAL

• The crankcase must be separated to service the crankshaft and piston/connecting rod. Refer to section 11 for crankcase separation and assembly.

• Mark and store the connecting rods, bearing caps, pistons and bearing inserts to be sure of their correct locations during reassembly.

• The crankpin and main journal bearing inserts are select fit and are identified by color codes. Select replacement bearings from the code tables. After selecting new bearings, recheck the oil clearance with plastigauge. Incorrect oil clearance can cause major engine damage.

SPECIFICATIONS

Unit: mm (in)

ITEM

STANDARD

SERVICE LIMIT

■ Crankshaft

Connecting rod side clearance

0.10 - 0.25 (0.004- 0.010)

0.30 (0.012)

Crankpin bearing oil clearance

0.028 - 0.052 (0.0011 - 0.0020)

0.06 (0.002)

Main journal bearing oil clearance

0.020 0.038 (0.0008 - 0.0015)

0.05 (0.002)

Runout

1

-

0.05 (0.002)

12

Piston, piston

Piston O.D. at 15 mm (0.6 in) from bottom

66.965 - 66.985 (2.6364 - 2.6372)

66.90 (2.634)

rings

Piston pin bore I.D.

17.002 - 17.008 (0.6694 - 0.6696)

17.02 (0.670)

Piston pin O.D.

16.994 - 17.000 (0.6691 - 0.G693)

16.98 (0.669)

Piston to piston pin clearance

0.002 - 0.014 (0.0001 - 0.0006)

0.04 (0.002)

Piston ring end gap

Top

0.10-0.20 (0.004-0.008)

0.4 (0.02)

Second

0.18-0 30 (0.007-0.012)

0.5 (0.02)

Oil (side rail)

0.2-0.7 (0.01 -0.03)

1.0 (0.04)

Piston ring-to-ring

Top

0.020 - 0.050 (0.0008 - 0.0020)

0.08 (0.003)

groove clearance

Second

0.015-0.050(0.0006-0.0020)

0.08 (0.003)

Cylinder

I.D.

67.000 - 67.015 (2.6378 - 2.6384)

67.10 (2.642)

r

Out-of-round

_

0.10(0.004)

Taper

-

0.10(0.004)

Warpage

-

0.10(0.004)

I Cylinder-to-piston clearance

0.015 - 0.050 (0.0006 0.0022)

0.10(0.004)

I Connecting rod

small end I.D.

; 17.016 - 17.034 (0.6699 0.6706)

17.04 (0.671)

Connecting rod-to-piston pin clearance

0.016-0.040 (0.0006 0.0016)

0.06 (0.002)

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