Kawasaki Ninja Service Manual: Connecting Rod Big End Bearing Insert/Crankpin Wear Inspection

Kawasaki Ninja Service Manual / Crankshaft/Transmission / Crankshaft and Connecting Rods / Connecting Rod Big End Bearing Insert/Crankpin Wear Inspection

Connecting Rod Big End Bearing Insert/Crankpin Wear Inspection


NOTE

Do not move the connecting rod and crankshaft during clearance measurement.

Remove the connecting rod big end again, measure each clearance between the bearing insert and crankpin [A] using plastigage (press gauge) [B].

NOTICE

After measurement, replace the connecting rod bolts and nuts.

Connecting Rod Big End Bearing Insert/Crankpin Clearance

Standard: 0.030 0.060 mm
(0.0012 0.0024 in.)


Service Limit: 0.10 mm (0.0039 in.)

If the clearance is within the standard, no bearing replacement is required.

If the clearance is between 0.061 mm (0.0024 in.) and the service limit (0.10 mm, 0.0039 in.), replace the bearing inserts [A] with inserts painted blue [B]. Check insert/ crankpin clearance with the plastigage. The clearance may exceed the standard slightly, but it must not be less than the minimum in order to avoid bearing seizure.

If the clearance exceeds the service limit, measure the diameter of the crankpins.

Connecting Rod Big End Bearing Insert/Crankpin Wear Inspection


Crankpin Diameter

Standard: 34.484 34.500 mm
(1.3576 1.3583 in.)


Service Limit: 34.47 mm (1.3571 in.)

Crankpin Diameter Marks

None 34.484 34.492 mm (1.3576
1.3580 in.)

34.493
34.500 mm (1.3580
1.3583 in.)


Connecting Rod Big End Bearing Insert/Crankpin Wear Inspection


: Crankpin Diameter Marks (“” or
No Mark)

NOTE

The mark already on the big end should almost coincide with the measurement.

Connecting Rod Big End Inside Diameter Marks

None 37.500   37.508 mm
(1.4764 1.4767 in.)


37.509
37.516 mm (1.4767
1.4770 in.)


Connecting Rod Big End Bearing Insert/Crankpin Wear Inspection


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

Connecting Rod Big End Bearing Insert/Crankpin Wear Inspection


Connecting Rod Big End Bearing Insert/Crankpin Wear Inspection


Connecting Rod Big End Side Clearance Inspection
Measure connecting rod big end side clearance. Insert a thickness gauge [A] between the big end and either crank web to determine clearance. Connecting Rod Big End Side Clearance Standard: 0. ...

Crankshaft Side Clearance Inspection
Insert a thickness gauge [A] between the thrust washer [B] on the crankcase and the crank web [C] at the #3 main journal to determine clearance. If the clearance exceeds the service limit, r ...

Other materials:

Stick Coil Inspection
Remove the stick coils (see Stick Coil Removal). Measure the primary winding resistance [A] as follows. Connect the hand tester between the coil terminals. Set the tester to the × 1 Ω range, and read the tester. Measure the secondary winding resistance [B] as follows. Conn ...

Check 3-6: Neutral Indicator Light (LED) Inspection
Connect the leads in the same circuit as Check 3-2. Connect the terminal [8] to the battery (–) terminal. Check that the neutral indicator light (LED) [A] goes on. If the indicator light does not go on, replace the meter unit. ...

Steering Play Inspection
Remove the lower fairings (see Lower Fairing Removal in the Frame chapter). Raise the front wheel off the ground with the jack. Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1608 With the front wheel pointing straight ahead, alternately tap each end of the handlebar. The f ...