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Table of Contents
ENGINE
7. Remove the rod cap.
8. Measure the width of t h e flattened
Plastigage according t o manufacturer's
instructions (Figure 134). T h e standard
connecting rod big-end bearing clearance is
0.0016 in. (0.04 mm). The maximum (service
limit) is 0.004 in. (0.1 mm).
9. Compare both ends of the Plastigage strip.
A difference of 0.001 in. (0.025 mm) or more
indicates a tapered journal (which should be
reground) or a bent or twisted rod. Confirm
with micrometer measurement of the journal
OD.
10. If the clearance is larger than the service
limit, measure the O D of the crankpin journal
with a micrometer. The minimum crankpin
journal O.D. (service limit) is given in Table 1.
a. Ifthe OD is smaller than the service limit,
the crankshaft should be replaced.
b. If the OD is larger than the service limit,
install new bearing inserts. Always
replace all 8 inserts at the same time.
Several different insert thicknesses are
available and they are color-coded for
size. Refer to Table 1 for the insert
thickness.
c. Recheck the clearance with the new
inserts. The clearance should be less than
the service limit and as close to standard
as possible.
NOTE
You can install the thinnest new inserts,
recheck clearance and install thicker
inserts
if
the clearance wasn't correct or
you can calculate the required insert
thickness:
1.
Assemble the connecting rod and cap
without the inserts and measure the rod
big-end ID. The cap must be with its
original rod, with the weight mark on the
end of the cap matching the mark on the
rod (B,
Figure 128).
Install the cap nuts
finger-tight, then torque t h e m as
speciJied in
Table
2.
2. Subtract the crankpin journal OD
from the rod big-end ID, then subtract
the standard clearance-0.0016
in.
(0.04 mm). The number you get will be
twice the thickness of the required
inserts.
3. Divide by 2 for the appropriate insert
thickness.
1 1. Repeat for each connecting rod.
12. Clean and oil the crankpin journals and
insert faces.
13. Install t h e bearing inserts in each
connecting rod and cap. Make sure their
locking tabs are seated in the notches (Figure
132).
NOTE
I f the old inserts are reused, be sure they
are installed in their original positions to
prevent rapid wear.
Assembly
1. Install t h e b e a r i n g inserts in each
connecting rod and cap. Make sure their
locking tabs are seated in the notches (Figure
132).
NOTE
I f the old inserts are reused, be sure they
are installed in their original positions to
prevent rapid wear.
2. Oil the rod bearing inserts and crankpins.
3. Install each rod, one at a time, on the proper
crankpin, with No. 1 starting at the alternator
end of the crankshaft. The cap must be with its
original rod, with the weight mark on the end of
the cap matching the mark on the rod (B,
Figure 128).
4. Install the cap nuts finger-tight, then torque
them as specified in Table 2.
5. Install the remaining rods in the same
manner.
CAM CHAIN INSPECTION
Pull the cam chain taut with about a 10 1b. (5
kg) tension and measure the length from the 1st
pin to the 2
l
st pin (Figure 135). If the chain is
longer than the service limit given in Table 1,
install a new chain.
PRIMARY CHAIN INSPECTION
The primary chain wear is inspected by
measuring chain play with the crankshaft and
secondary shaft installed in the engine (Figure
117); see
Crankcase Separation
in this chapter.
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   Also See for Kawasaki KZ500

This manual is also suitable for:

Zx550Kz550Kzx550

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