Crankshaft Removal
Split the crankcase (See Crankcase Splitting).
Remove:
- Camshaft Chain [A]
- Crankshaft [B]
![](https://motoinstruction.ru/img/kawasaki/23/128653.jpg)
Crankshaft Installation
Note: Olf the crankshaft is replaced with a new one, refer to the Connecting Rod Big End Bearing/Crankshaft Main Bearing Insert Selection in the Specifications.
Caution: If the crankshaft, bearing inserts, or crankcase halves are replaced with new ones, select the bearing inserts and check clearance with a plastigage (press gauge) before assembling engine to be sure the correct bearing inserts are installed.
- Apply molybdenum disulfide oil solution to the crankshaft main bearing inserts.
- Align [A] the timing mark on the balancer gear [B] with the timing mark on the balancer drive gear [C] of the crankshaft.
![](https://motoinstruction.ru/img/kawasaki/23/128654.jpg)
- Install the rankshaft with the camshaft chain [A] hanging on it.
![](https://motoinstruction.ru/img/kawasaki/23/128655.jpg)
Connecting Rod Removal
- Split the crankcase (See Crankcase Splitting).
- Remove the connecting rod nuts [A].
- Remove the crankshaft (See Crankshaft Removal).
Note: OMark and record the locations of the connecting rods and their big end caps so that they can be reassembled in their original positions.
Remove the connecting rods from the crankshaft.
Caution: Discard the connecting rod bolts. To prevent damage to the crankpin surfaces, do not allow the connecting rod bolts to bump against the crankpins.
![](https://motoinstruction.ru/img/kawasaki/23/128656.jpg)
Connecting Rod Installation
Caution: 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]: "O" or no mark
![](https://motoinstruction.ru/img/kawasaki/23/128657.jpg)
Caution: If the connecting rods, big end bearing inserts, or crankshaft are replaced with new ones, select the bearing insert and check clearance with a plasti-gage (press gauge) before assembling engine to be sure the correct bearing inserts are installed.
- Apply molybdenum disulfide oil solution [A] to the inner surfaces of upper and lower bearing inserts.
The molybdenum disulfide oil solution is a mixture of engine oil and molybdenum disulfide grease with a weight ratio (10 : 1).
Do not apply any grease or oil [B] to the cap inside and cap insert outside.
Install the inserts so that their nails [C] are on the same side and fit them into the recess of the connecting rod and cap.
![](https://motoinstruction.ru/img/kawasaki/23/128658.jpg)
Caution: 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]
- Remove debris and clean the surface of inserts.
- Apply molybdenum disulfide oil solution [MO] to the threads and seating surfaces of the big end nuts and bolts.
![](https://motoinstruction.ru/img/kawasaki/23/128659.jpg)
- Install the crankshaft (See Crankshaft Installation).
- Install each connecting rod on its original crankpin.
Note: Install each connecting rod so that its oil jet [A] faces the exhaust side (the front [B]) (See Engine Oil Flow Chart in the Engine Lubrication System chapter).
- Install the cap on the connecting rod, aligning the weight and diameter marks.
![](https://motoinstruction.ru/img/kawasaki/23/128660.jpg)
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.
Caution: 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.
Caution! 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
- Be sure to clean the bolts, nuts, and connecting rods thoroughly with a high-flash point solvent, because the new connecting rods, bolts, and nuts are treated with an anti-rust solution.
Warning: Clean the bolts, nuts, and connecting rods in a well -ventilated area, and take care that there is no spark or flame anywhere near the working area. This includes any appliance with a pilot light. Because of the danger of highly flammable liquids, do not use gasoline or low-flash point solvents to clean them.
Caution: Immediately dry the bolts and nuts with compressed air after cleaning. Clean and dry the bolts and nuts completely.
- Install new bolts in reused connecting rods.
- Dent both bolt head and bolt tip with a punch as shown.
- Before tightening, use a point micrometer to measure the length of new connecting rod bolts and record the values to find the bolt stretch.
- Connecting Rod [A]
- Mark here with a punch [B].
- Nuts [C]
- Fit micrometer pins into punch marks [D].
- Apply a small amount of molybdenum disulfide oil solution to the following.
- Threads of Nuts and Bolts
- Seating Surfaces of Nuts and Con-rods
- Tighten the big end nuts until the bolt elongation reaches the length specified in the table.
- Check the length of the connecting rod bolts.
If the stretch is more than the usable range, the bolt has stretched too much. An overelongated bolt may break in use.
![](https://motoinstruction.ru/img/kawasaki/23/128661.jpg)
Bolt Length after tightening − Bolt Length before tightening − Bolt Stretch
Connecting Rod Assy | Bolt | Nut | Usable Range of Connecting Rod Bolt Stretch |
New | Use the bolts attached to new con-rod. | Attached to new con-rod | 0.24-0.36 mm (0.0094-0.0142 in.) |
New | |||
Used | Replace the bolts with new ones. | Used | 0.20-0.32 mm (0.0079-0.0126 in.) |
New |
(2) Rotation Angle Method
If you don't have a point micrometer, you may tighten the nuts using the "Rotation Angle Method".
- Be sure to clean the bolts and nuts thoroughly with a high -flash point solvent, because the new bolts and nuts are treated with an anti-rust solution.
Warning: Clean the bolts and nuts in a well-ventilated area, and take care that there is no spark or flame anywhere near the working area. This includes any appliance with a pilot light. Because of the danger or highly flammable liquids, do not use gasoline or low-flash point solvents to clean them.
Caution: Immediately dry the bolts and nuts with compressed air after cleaning.
- Clean and dry the bolts and nuts completely.
- Install new bolts in reused connecting rods.
- Apply a small amount of molybdenum disulfide oil solution to the following.
- Threads [A] of Nuts and Bolts
- Seating Surfaces [B] of Nuts and Con-rods
![](https://motoinstruction.ru/img/kawasaki/23/128662.jpg)
- First, tighten the nuts to the specified torque. See the table below.
- Next, tighten the nuts 120°±5°.
Mark [A] the connecting rod big end caps and nuts so that nuts can be turned 120° [B] properly.
![](https://motoinstruction.ru/img/kawasaki/23/128663.jpg)
Connecting Rod Assy | Bolt | Nut | Torque + Angle Nm (kgf·m, ft?lb) |
New | Use the bolts attached to new con-rod. | Attached to new con-rod | 18 (1.8, 13.0) + 120° |
New | 20 (2.0, 15) + 120° | ||
Used | Replace the bolts with new ones. | Used | 24 (2.4, 17.4) + 120° |
New | 25 (2.6, 18.8) + 120° |
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 residue that may have accumulated in the passages.
Connecting Rod Bend
- 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 connecting rod bend exceeds the service limit, the connecting rod must be replaced.
![](https://motoinstruction.ru/img/kawasaki/23/128664.jpg)
Connecting Rod Bend
Service Limit: TIR 0.2/100 mm (0.008/3.94 in.)
Connecting Rod Twist
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 mm (3.94 in.) length of the arbor to determine the amount of connecting rod twist.
If connecting rod twist exceeds the service limit, the connecting rod must be replaced.
Connecting Rod Twist
Service Limit: TIR 0.2/100 mm (0.008/3.94 in.)
![](https://motoinstruction.ru/img/kawasaki/23/128665.jpg)
Connecting Rod Big End Side Clearance
- Measure connecting rod big end side clearance.
lnsert 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.)
If the clearance exceeds the service limit, replace the connecting rod with new one and then check clearance again. If clearance is too large after connecting rod replacement, the crankshaft also must be replaced.
![](https://motoinstruction.ru/img/kawasaki/23/128666.jpg)
Connecting Rod Big End Bearing Insert/Crankpin Wear
- Measure the bearing insert/crankpin [B] clearance with plastigage [A].
- Tighten the big end nuts to the specified torque (See Connecting Rod Installation).
Note: Do not move the connecting rod and crankshaft during clearance measurement.
![](https://motoinstruction.ru/img/kawasaki/23/128667.jpg)
Caution: After measurement, replace the connecting rod bolts.
- Connecting Rod Big End Bearing Insert/Crankpin
Clearance
Standard: 0.017-0.041 mm (0.0007-0.0016 in.)
Service Limit: 0.08 mm (0.0031 in.)
If the clearance is within the standard, no bearing replacement is required.
If the clearance is between 0.042 mm (0.00165 in.) and the service limit (0.08 mm, 0.0031 in.), replace the bearing inserts [A] with inserts painted blue [B]. Check in-sert/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.
![](https://motoinstruction.ru/img/kawasaki/23/128668.jpg)
Crankpin Diameter
Standard: 37.984-38.000 mm (1.4954-1.4961 in.)
Service Limit: 37.97 mm (1.4949 in.)
If any crankpin has worn past the service limit, replace the crankshaft with a new one.
If the measured crankpin diameters are not less than the service limit, but do not coincide with the original diameter markings on the crankshaft, make new marks on it.
Crankpin Diameter Marks
- None 37.984-37.992 mm (1.4954-1.4957 in.), 37.993-38.000 mm (1.4958-1.4961 in.)
- Crankpin Diameter Marks, "О" or no mark.
- Measure the connecting rod big end inside diameter, and mark each connecting rod big end in accordance with the inside diameter.
- Tighten the connecting rod big end nuts to the specified torque (See Connecting Rod Installation).
![](https://motoinstruction.ru/img/kawasaki/23/128669.jpg)
Note. The mark already on the big end should almost coincide with the measurement.
- Connecting Rod Big End Inside Diameter Marks None 41.000-41.008 mm (1.6142-1.6145 in.), 41.009-41.016 mm (1.6145-1.6148 in.)
- Big End Cap [A]
- Connecting Rod [B]
- Weight Mark, Alphabet [C]
- Diameter Mark (Around Weight Mark) [D]: "О" or no mark
![](https://motoinstruction.ru/img/kawasaki/23/128670.jpg)
- Select the proper bearing insert [A] in accordance with the combination of the connecting rod and crankshaft coding.
- Size Color [B]
Con-rod Big End Inside Diameter Marking | Crankpin Diameter Marking | Bearing Insert | |
Size Color | Part Number | ||
None | o | Brown | 92139-0116 |
None | None | Black | 92139-0115 |
o | o | ||
o | None | Blue | 92139-0114 |
- Install the new inserts in the connecting rod and check insert/crankpin clearance with the plastigage.
![](https://motoinstruction.ru/img/kawasaki/23/128671.jpg)
Crankshaft Side Clearance
- Insert a thickness gauge [A] between the crankcase main bearing and the crank web at the No. 2 journal [B] to determine clearance.
If the clearance exceeds the service limit, replace the crankcase halves as a set.
![](https://motoinstruction.ru/img/kawasaki/23/128672.jpg)
Note. OThe upper and lower crankcase halves are machined at the factory in the assembled state, so the crankcase halves must be replaced as a set.
Crankshaft Side Clearance
Standard: 0.05-0.20 mm (0.0020-0.0079 in.)
Service Limit: 0.40 mm (0.0157 in.)
Crankshaft Runout
Measure the crankshaft runout.
If the measurement exceeds the service limit, replace the crankshaft.
Crankshaft Runout
Standard: TIR 0.02 mm (0.0008 in.) or less
Service Limit: TIR 0.05 mm (0.0020 in.)
![](https://motoinstruction.ru/img/kawasaki/23/128673.jpg)
Crankshaft Main Bearing Insert/Journal Wear
- Using a plastigage (press gauge) [A], measure the bearing insert/journal [B] clearance.
Note: Tighten the crankcase bolts to the specified torque (See Crankcase Assembly). Do not turn the crankshaft during clearance measurement.
Journal clearance less than 0.025 mm (0.00098 in.) can not be measured by plastigage, however, using genuine parts maintains the minimum standard clearance.
![](https://motoinstruction.ru/img/kawasaki/23/128674.jpg)
Crankshaft Main Bearing Insert/Journal Clearance Standard: 0.012-0.036 mm (0.0005-0.0014 in.)
Service Limit: 0.07 mm (0.0028 in.)
If the clearance is within the standard, no bearing replacement is required.
If the clearance is between 0.037 mm (0.0015 in.) and the service limit (0.07 mm, 0.0028 in.), replace the bearing inserts [A] with inserts painted blue [B]. Check insert/journal 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 crankshaft main journal.
![](https://motoinstruction.ru/img/kawasaki/23/128675.jpg)
Crankshaft Main Journal Diameter
Standard: 37.984-38.000 mm (1.4954-1.4961 in.)
Service Limit: 37.96 mm (1.4945 in.)
If any journal has worn past the service limit, replace the crankshaft with a new one.
If the measured journal diameters are not less than the service limit, but do not coincide with the original diameter markings on the crankshaft, make new marks on it.
Crankshaft Main Journal Diameter Marks
- None 37.984-37.992 mm (1.4954-1.4957 in.), 37.993-38.000 mm (1.4958-1.4961 in.)
- Crankshaft Main Journal Diameter Marks, "1" or no mark
![](https://motoinstruction.ru/img/kawasaki/23/128676.jpg)
- Measure the main bearing inside diameter, and mark the upper crankcase half in accordance with the inside diameter.
Crankcase Main Bearing Inside Diameter
- Marks: "O" or no mark.
- Tighten the crankcase bolts to the specified torque (See Crankcase Assembly).
![](https://motoinstruction.ru/img/kawasaki/23/128677.jpg)
Note. OThe mark already on the upper crankcase half should almost coincide with the measurement.
Crankcase Main Bearing Inside Diameter Marks
- None 41.009-41.016 mm (1.6145-1.6148 in.), 41.000-41.008 mm (1.6142-1.6145 in.)
- Crankcase Main Bearing Inside Diameter Marks, "O" mark or no mark
- No.1 Journal [A]
- No.2 Journal [B]
- No.3 Journal [C]
- Select the proper bearing insert [A] in accordance with the combination of the crankcase and crankshaft coding.
- Size Color [B]
![](https://motoinstruction.ru/img/kawasaki/23/128678.jpg)
Crankcase Main Bearing Inside Diameter Marking | Crankshaft Main Journal Diameter Marking | Bearing Insert* | |
Size Color | Part Number | ||
О | 1 | Brown | 92028-1905 |
None | 1 | Black | 92028-1904 |
О | None | ||
None | None | Blue | 92028-1903 |
*The bearing inserts for Nos. 1, 2 and 3 journals have oil groove.
- Install the new inserts in the crankcase halves and check insert/journal clearance with the plastigage.