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0.003 is a lot to remove by hone. That would typically require boring first. It is also imperative that the bore centerlines are matched which is why the honing bar is used. The amount removed from the caps for bearing bore resizing is trivial in your case. The effect on the roundness of the...

If the bearing bore is too small you simply hone it on the line hone machine. You won't touch the rear seal bore. That goes out of round when you mill the caps to reduce the bore diameter.

Well gosh darn, I'm full of manure. I just popped the inserts out of my original 1986 block and it has dates ranging from 1981 to 1986. Never seen that before. My 6.5 engine was all 2004. The factory service manual is available online and describes the markings on the block in relation to the...

Those bearings have two different dates on them, 81 and 85. No way the engine came new with those.

I had a good conversation about this with my local Yamaha dealer. The Japanese motorcycle manufacturers use select fit pistons and cylinders. Cylinders are A-D with A being largest and D being smallest cylinder The dealers stocks D pistons as they are the smallest and fit all bores. The point...