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Crankshaft/connecting Rods; Crankshaft Removal; Crankshaft Installation; Connecting Rod Removal - Kawasaki vn 800 classic Service Manual

1996-2006.
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9-12 CRANKSHAFT/TRANSMISSION

Crankshaft/Connecting Rods

Crankshaft Removal

•
Split the crankcase (see Crankcase Splitting).
•
Remove the crankshaft.

Crankshaft Installation

•
Insert the crankshaft tapered end in to the left crankcase
[A].
•
Install the left connecting rod [B] into the rear cylinder
opening [C], and right connecting rod [D] into the front
cylinder opening [E].

Connecting Rod Removal

•
Remove the crankshaft (see Crankshaft Removal).
○
Mark 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 rod big end cap nuts, and take
off the rod and cap with the bearing inserts.

Connecting Rod Installation

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 (Around Weight Mark) [D]: "O" or no
mark.
If the connecting rods, bearing inserts, or crank-
shaft are replaced with new ones, select the bearing
insert and check clearance with a plastigage (press
gauge) before assembling engine to be sure the cor-
rect bearing inserts are installed.
•
Apply engine oil to the inner surface of upper and lower
bearing inserts [A].
•
Apply a small amount of molybdenum disulfide oil to the
threads [B] and seating surface [C] of the connecting rod
big end cap nuts.
•
Tighten:
Torque - Connecting Rod Big End Cap Nuts: 46 N·m (4.7
kgf·m, 34 ft·lb)
NOTE
CAUTION
CAUTION
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