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Crankshaft/connecting Rod Cleaning; Connecting Rod Bend Inspection; Connecting Rod Twist Inspection; Connecting Rod Big End Side Clearance Inspection - Kawasaki ninja zx-6rr Service Manual

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Crankshaft and 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 inserts, 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 105 mm (4.13 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: TIR 0.2/100 mm (0.008/3.94 in.)

Connecting Rod Twist Inspection

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 de-
termine 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: TIR 0.2/100 mm (0.008/3.94 in.)

Connecting Rod Big End Side Clearance Inspection

Measure connecting rod big end side clearance.
Insert a thickness gauge [A] between the big end and ei-
ther crank web to determine clearance.
Connecting Rod Big End Side Clearance
0.13 ∼ 0.33 mm (0.0051 ∼ 0.0130 in.)
Standard:
Service Limit: 0.53 mm (0.021 in.)
If the clearance exceeds the service limit, replace the con-
necting rod with new one and then check clearance again.
If clearance is too large after connecting rod replacement,
the crankshaft also must be replaced.
CRANKSHAFT/TRANSMISSION 9-17

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