Kawasaki Ninja Service Manual: Connecting Rod Big End Side Clearance Inspection

Kawasaki Ninja Service Manual / Crankshaft/Transmission / Crankshaft and Connecting Rods / Connecting Rod Big End Side Clearance Inspection

Insert a thickness gauge [A] between the big end and either crank web to determine clearance.

Connecting Rod Big End Side Clearance

Standard: 0.13 0.38 mm
(0.0051 0.0150 in.)


Service Limit: 0.58 mm (0.023 in.)

Connecting Rod Big End Side Clearance Inspection


If the clearance exceeds the service limit, replace the connecting rod with new one and then check clearance again.

If the clearance is too large after connecting rod replacement, the crankshaft also must be replaced.

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 ...

Connecting Rod Big End Bearing Insert/Crankpin Wear Inspection
Remove the connecting rod big end (see Connecting Rod Removal). Cut strips of plastigage to crankpin width. Place a strip on the crankpin parallel to the crankshaft installed in the correct ...

Other materials:

Check 3-7 Stop Watch Inspection
Connect the leads in the same circuit as Check 3-2. By pushing the upper button each time to set the stop watch mode. Connect the insulated auxiliary lead processed insulation to the terminal [13] as shown in the figure, then stop watch start to count. While count the stop watch, conn ...

Engine Stop Switch Operation Inspection
First Step Set the gear position in the neutral position. Turn the ignition switch to ON. Turn the engine stop switch to stop position [A]. Push the starter button. The engine does not start. If the engine starts, inspect the engine stop switch (see Switch Inspection in the Electri ...

Tire Removal
Remove: Wheels (see Front/Rear Wheel Removal) Valve Core (Let out the air) To maintain wheel balance, mark the valve stem position on the tire with chalk so that the tire can be reinstalled in the same position. Chalk Mark or Yellow Mark [A] Valve Stem [B] Align [C] Lu ...