Kawasaki Ninja Service Manual: Connecting Rod Installation

Kawasaki Ninja Service Manual / Crankshaft/Transmission / Crankshaft and Connecting Rods / Connecting Rod Installation

NOTICE

To minimize vibration, the connecting rods should have the same weight mark.

Big End Cap [A] Connecting Rod [B] Weight Mark, Alphabet [C] Diameter Mark [D] (“” or No Mark)

Connecting Rod Installation


NOTICE

If the connecting rods, big end bearing inserts, or crankshaft are replaced with new ones, select the bearing insert and check clearance with a plastigage (press gauge) before assembling engine to be sure the correct bearing inserts are installed.

Connecting Rod Installation


NOTICE

Wrong application of oil and grease could cause bearing damage.

When installing the inserts [A], be careful not to damage the insert surface with the edge of the connecting rod [B] or the cap [C]. One way to install inserts is as follows.

Installation [D] to Cap Installation [E] to Connecting Rod Push [F] Spare Dowel Pin [G] Connecting Rod Bolts [H]

Connecting Rod Installation


The connecting rod big end is bolted using the “plastic region fastening method”.

This method precisely achieves the needed clamping force without exceeding it unnecessarily, allowing the use of thinner, lighter bolts further decreasing connecting rod weight.

There are two types of the plastic region fastening. One is a bolt length measurement method and other is a rotation angle method. Observe one of the following two, but the bolt length measurement method is preferable because this is a more reliable way to tighten the big end nuts.

NOTICE

The connecting rod bolts are designed to stretch when tightened. Never reuse the connecting rod bolts. See the table below for correct bolt and nut usage.

NOTICE

Be careful not to overtighten the nuts. The bolts must be positioned on the seating surface correctly to prevent the bolt heads from hitting the crankcase.

(1) Bolt Length Measurement Method

WARNING

Gasoline and low flash-point solvents can be flammable and/or explosive and cause severe burns. Clean the bolts, nuts, and connecting rods in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area; this includes any appliance with a pilot light.

Do not use gasoline or a low flash-point solvent to clean them.

NOTICE

Immediately dry the bolts and nuts with compressed air after cleaning. Clean and dry the bolts and nuts completely.

If the connecting rod assembly was replaced, use the bolts and nuts attached to the new connecting rod assembly.

Connecting Rod Installation


Connecting Rod Installation


Bolt Length after tightening – Bolt Length before tightening = Bolt Stretch

Connecting Rod Bolt Stretch Usable Range: 0.24 0.34 mm (0.0094
0.0134 in.)


If the stretch is more than the usable range, the bolt has stretched too much. An overelongated bolt may break in use.

(2) Rotation Angle Method

If you do not have a point micrometer, you may tighten the nuts using the “Rotation Angle Method”.

WARNING

Gasoline and low flash-point solvents can be flammable and/or explosive and cause severe burns. Clean the bolts, nuts, and connecting rods in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area; this includes any appliance with a pilot light.

Do not use gasoline or a low flash-point solvent to clean them.

NOTICE

Immediately dry the bolts and nuts with compressed air after cleaning. Clean and dry the bolts and nuts completely.

If the connecting rod assembly was replaced, use the bolts and nuts attached to the new connecting rod assembly.

Connecting Rod Installation


Mark [A] the connecting rod big end caps and nuts so that nuts can be turned 150° [B] properly.


Connecting Rod Installation


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