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:

Brake Fluid Level Inspection
Check that the brake fluid level in the front brake reservoir [A] is above the lower level line [B]. NOTE Hold the reservoir horizontal by turning the handlebar when checking brake fluid level. If the fluid level is lower than the lower level line, fill the reservoir to the upper lev ...

Front Forks/Rear Shock Absorber Operation Inspection
Pump the forks down and up [A] 4 or 5 times, and inspect the smooth stroke. If the forks do not smoothly or noise is found, inspect the fork oil level or fork clamps (see Front Fork Oil Change in the Suspension chapter). Pump the rear seat down and up [A] 4 or 5 times, and inspec ...

Engine Oil Flow Chart
1. Oil Screen 2. Oil Pump 3. Oil Pressure Relief Valve 4. Oil Filter 5. Oil Pipe 6. Oil Cooler 7. Balancer Oil Passage 8. Main Oil Passage 9. Crankshaft Oil Passage 10. Oil Pressure Switch 11. Camshaft Oil Passages 12. Drive Shaft Oil Passage 13. Output Shaft Oil Passage 14. Starter ...