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Crankshaft/connecting Rod Cleaning; Connecting Rod Bend Inspection; Connecting Rod Twist Inspection; Connecting Rod Big End Bearing Insert/crankpin Wear Inspection - Kawasaki vn 800 classic Service Manual

1996-2006.
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Crankshaft/Connecting Rods

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 Inspection

Remove the connecting rod big end bearing insets, and
reinstall the connecting rod big end cap.
Select an arbor [A] of the same diameter as the connect-
ing rod big end, and insert the arbor through the connect-
ing 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 con-
necting rod must be replaced.
Connecting Rod Bend
Service Limit:

Connecting Rod Twist Inspection

With the big-end arbor [A] still on V block [C], hold the con-
necting rod horizontally and measure the amount that the
arbor [B] varies from being parallel 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 con-
necting rod must be replaced.
Connecting Rod Twist
Service Limit:
Connecting Rod Big End Bearing Insert/Crankpin
Wear Inspection
Measure the bearing insert/crankpin [A] clearance with a
plastigage [B].
Tighten the connecting rod big end cap nuts to the speci-
fied torque (see Connecting Rod Installation).
Do not move the connecting rod and crankshaft during
clearance measurement.
Connecting Rod Big End Bearing Insert/Crankpin
Clearance
Standard:
Service Limit:
TIR 0.2/100 mm (0.008/3.94 in.)
TIR 0.2/100 mm (0.008/3.94 in.)
NOTE
0.026 ∼ 0.054 mm (0.0010 ∼ 0.0021 in.)
0.09 mm (0.035 in.)
CRANKSHAFT/TRANSMISSION 9-13

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Vulcan 800 classic

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