REPLACEMENT BEARING THICKNESS
RED .0783 -- .0785 (1.990 -- 1.995mm)
YELLOW .0785 -- .0787 (1.995 -- 2.000mm)
BLUE .0787 -- .0789 (2.000 -- 2.005mm)
GREEN .0789 -- .0791 (2.005 -- 2.010mm)
BROWN .0791 -- .0793 (2.010 -- 2.015mm)
SPECIFIED OIL CLEARANCE: ___________________
MEASURED OIL CLEARANCE: __________________
ORIGINAL INSTALLED BEARING COLOR / THICKNESS: _____________________
.0003″ -- .002″ (.01mm-- .064mm )
ENGINE DISASSEMBLY / ASSEMBLY
4.372004 Four Stroke PWC Service Manual
Connecting Rod Insp ectio n
Measure big end oil clearance.
NOTE: Do not move crankshaft or connect-
ing rods until measurement process is com-
pleted.
1. Remove lower connecting rod caps.
2. Place a piece of Plastigauge across the journal
surface. Install lower rod caps with journal bearings
installed.
3. Torque rod bolts to specified torque.
4. Remove caps and measure each compressed piece of
Plastigauge .
5. Reference bearing replacement guide if bearing oil
clearance is out of specification.
S Out of specification: Replace connecting rod bearings
Measure small end inside diameter.
S Out of specification: Replace connecting rod
Connecting Rod Bearing Replacement Guide
Replacement of the connecting rod bearings is required when the bearing oil clearance is out of specification.
Use this guide to select new bearings.
NOTE: Bearing color code is imprinted on the side of each bearing.
If the measured clearance is within specification, replace with new bearings with the same color code.
If the oil clearance is outside of specification, install the BLUE color--coded bearings and re--measure oil clear-
ance. If the measured clearance is too small, install either a RED or YELLOW bearing. If the measured clearance
is too large, install either a BROWN or GREEN bearing.
If the used bearings reveal an oil clearance of .04 and .05mm, install new bearings with the same color code.
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