Finally getting back to this, between last night and tonight I've now got some crank measurements.
On the crank seal grooves worn in, here's what I ended up with:
Both clutch and flywheel sides
Crankshaft diameter .....0.9825
Diameter measured in the groove....0.9800
this gives me an actual groove depth of 0.00125
The other measurement I took was the crankshaft runout. The book shows setting the crank up in centering spindles which I don't have, but I believe I still got good measurements using the surface plate and V-blocks.
Here's what book shows:
My measurements on both sides netted me a variance of 0.001
And this was my setup:
The book did show other measurements to take, such as "Connecting Rod Bend\twist", "Connecting Rod Big End radial clearance" and "Connecting Rod Big End side clearance", but my crank and connecting rod feel very good with no noticeable looseness anywhere. So curse my laziness, I skipped these.
The book showed a service limit measurement for the connecting rod small end to be.......0.789
This caused me to have an "
oh-s**t" moment because mine measures 0.827 which is 0.038 over the service limit.
At this time I don't think I'm going to sweat about it. With a new wrist pin bearing and piston pin I think it will survive. I'm not really that interested in having the crank split at this time and I'm not rebuilding a 10,000 rpm 450 four stroke. The important thing to me is that I know about it.
I'll just be mindful of this before I launch her over any jumps, I'll make a file note on it and move on. In the meantime I'll have to begin the search for a new crank and rod.