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:

Stem, Stem Bearing Removal
Remove: Upper Fairing Assembly (see Upper Fairing Assembly Removal in the Frame chapter) Front Fender (see Front Fender Removal in the Frame chapter) Front Wheel (see Front Wheel Removal in the Wheels/Tires chapter) Steering Stem Head with Handlebars (see Handlebar Removal) Fron ...

Battery Installation
Visually inspect the surface of the battery container. If any signs of cracking or electrolyte leakage from the sides of the battery. Put the battery into the rear fender Install the band [A]. Connect the positive (+) cable [B] (red cap) to the positive (+) terminal first, and then ...

Special Tools
Bearing Puller: 57001-135 Head Pipe Outer Race Press Shaft: 57001-1075 Steering Stem Nut Wrench: 57001-1100 Bearing Driver Set: 57001-1129 Steering Stem Bearing Driver, 42.5: 57001-1344 Steering Stem Bearing Driver Adapter, 41.5: 57001-1345 Head Pipe Outer Race Driver, 55: 57001- ...