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Connecting Rod Big End Radial Clearance; Connecting Rod Big End Side Clearance; Crankshaft Runout; Crankshaft Alignment - Kawasaki KLX110 Service Manual

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Crankshaft, Connecting Rod

Connecting Rod Big End Radial Clearance

Set the crankshaft in flywheel alignment jig or on V blocks, and place
a dial gauge [A] against the big end of the connecting rod.
Push [B] the connecting rod first towards the gauge and then in the
opposite direction. The difference between the two gauge readings
is the radial clearance.
If the radial clearance exceeds the service limit, the crankshaft should
be either replaced or disassembled and the crankpin, needle bearing,
and connecting rod big end examined for wear.
Connecting Rod Big End Radial Clearance
Standard:
Service Limit:

Connecting Rod Big End Side Clearance

Measure the side clearance [A] of the connecting rod with a thickness
gauge.
If the clearance exceeds the service limit, replace the crankshaft.
Connecting Rod Big End Side Clearance
Standard:
Service Limit:

Crankshaft Runout

Set the crankshaft in a flywheel alignment jig or on V blocks, and
place a dial gauge against the points indicated.
Turn the crankshaft slowly.
readings is the crankshaft runout.
Crankshaft Runout
Standard:
Service Limit:

Crankshaft Alignment

If the runout at either point exceeds the service limit, align the
flywheels so that the runout falls within the service limit.
In the case of horizontal misalignment, which is the most common,
strike the projecting rim of the flywheel with a plastic, soft lead, or
brass hammer as indicated in the figure.
Recheck the runout with a dial gauge, repeating the process until the
runout falls within the service limit.
Vertical misalignment is corrected either by driving a wedge in
between the flywheels, or by squeezing the flywheel rims in a vise,
depending on the nature of the misalignment.
0.009
0.023 mm
0.07 mm
0.1
0.2 mm
0.4 mm
The maximum difference in gauge
Less than 0.03 mm TIR
0.08 mm
CRANKSHAFT / TRANSMISSION 8-9

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