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Table of Contents
1982 AND LATER SERVICE INFORMATION
261
0
Main bearing bore marks
ase
half
15. If the clearance is larger than the service
limit, measure the OD of the crankshaft main
journal with a micrometer. The minimum
main journal OD (service limit) is given in
Table 10.
16. If the OD is smaller than the service
limit, the crankshaft should be replaced as
follows:
a. Check the upper crankcase half at the
points indicated in Figure 34 for main
bearing bore diameter marks. The
crankcase will be marked with an "0" or
there will be no mark representing each
bearing insert.
b. Purchase a new crankshaft. Then
cross-reference
the
main
journal
crankshaft diameter markings (Figure
35) with the upper crankcase half marks
(Figure 34). Refer to Table 12 to select
the new main bearing inserts for the new
crankshaft.
17. If the OD is larger than the service limit,
install new bearing inserts colored green.
Always replace all 10 inserts at the same time.
18. Recheck the clearance with the new
inserts or crankshaft. The clearance should be
less than the service limit and as close to
standard as possible. See Table 10.
19. Clean and oil the main bearing journals
and insert faces.
20. Install the bearing inserts in the crankcase
halves. Make sure their locking tabs are
seated in the notches.
NOTE
If the old inserts are reused, be sure
they are installed in their original
positionsfor minimum wear.
21. Reassemble the engine as described in
this supplement and Chapter Four of the
main book.
Connecting Rod
Bearing Clearance
1. Disassemble the crankcase as described in
Chapter Four of the basic book.
2. Make a note of the color on the edge of the
bearing insert (Figure 29). The colors are
brown, black or green.
3. Check the inside and outside surfaces of
the bearing inserts for wear, a bluish tint
(burned), flaking, abrasion or scoring. If the
inserts are good, they may be reused if
clearance is satisfactory. If any insert is
questionable, replace the entire set.
4. Wipe any oil from the crankpin journals
and the inserts.
5. Install the inserts in the connecting rod
and cap. Make sure their locking tabs are
seated in the notches.
NOTE
If
the old inserts are reused, be sure
they are installed in their original
positions to prevent rapid wear.
6. Place a strip of Plastigage on one crankpin
parallel to the crankshaft.
NOTE
Do not put Plastigage over the oil holes.
Do not rotate the crankshaft while the
Plastigage strips are in place.
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Zx550Kz550Kzx550

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