Kawasaki Ninja Service Manual: Connecting Rod Bend Inspection

Kawasaki Ninja Service Manual / Crankshaft/Transmission / Crankshaft and Connecting Rods / Connecting Rod Bend Inspection

Remove the connecting rod big end bearing inserts, and reinstall the connecting rod big end cap.
Select an arbor [A] of the same diameter as the connecting rod big end, and insert the arbor through the connecting rod big end.
Select an arbor of the same diameter as the piston pin and at least 100 mm (3.94 in.) long, and insert the arbor [B] through the connecting rod small end.
On a surface plate, set the big-end arbor on V block [C].
With the connecting rod held vertically, use a height gauge to measure the difference in the height of the arbor above the surface plate over a 100 mm (3.94 in.) length to determine the amount of connecting rod bend.

If the connecting rod bend exceeds the service limit, the connecting rod must be replaced.

Connecting Rod Bend Service Limit: TIR 0.2/100 mm (0.008/3.94 in.)

Connecting Rod Bend Inspection

Crankshaft/Connecting Rod Cleaning

After removing the connecting rods from the crankshaft, clean them with a high flash-point solvent. Blow the crankshaft oil passages with compressed air to remove any foreign particles or res ...

Connecting Rod Twist Inspection

With the big-end arbor [A] still on V block [C], hold the connecting rod horizontally and measure the amount that the arbor [B] varies from being paralleled with the surface plate over a 100 ...

Other materials:

General Lubrication
Lubricate the points shown below, with either motor oil or regular grease, in accordance with the Periodic Maintenance Chart or whenever the vehicle has been operated under wet or rainy conditions. Before lubricating each part, clean off any rusty spots with rust remover and wipe off any g ...

Nozzle Assy Assembly
Before assembling, blow away dirt or dust from the delivery pipes [A] by applying compressed air [B]. Replace the O-rings [A] of the joint pipe [B] with new ones. Apply engine oil to the new O-rings, and insert it to the delivery pipes [C] Insert the joint pipe so that the step ...

Clutch Cover Removal
Remove: Right Lower Fairing (see Lower Fairing Removal in the Frame chapter) Clutch Cable Lower End (see Cable Removal) Clutch Cover Bolts [A] Turn the release lever [A] counterclockwise as shown, and remove the clutch cover. About 90° [B] ...