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Kawasaki KZ1300-A1 Quick Reference Manual Page 111

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DISASSEMBLY -- ENGINE REMOVED
eRemove the drive shaft and secondary shaft (Pg. 101)
eMark the connecting rod big end caps as to location
so that they can be reinstalled in their original loca-
tions.
eRemove the nuts (6) and bolts (6), and pull off the
connecting rod big end caps.
~ ::dP::;e:l:a:,a~~:; ;;~:~!Ot~et~;a~~~
shaft jou rnals.
eSlip a 35 mm long hose onto each rod bolt as the cap
is
removed. This keeps the bolt from scratching the
bearing surface.
eLift off the crankshaft with the camshaft chain.
eSlip the camshaft chain off the
crankshaft.
Installation Notes:
1. There are oil passages running between the crank-
shaft journals.
Use compressed air to remove any
foreign particles or residue that may have accumu-
lated
in
these passages.
2. Be sure to replace the big end cap bolts (12) and
nuts (6) with new ones to get the correct tightening
force.
~ :::~s:o :~::e~u~~t ::~~s f:i~~ren~~IO=~
ing. with extensive engine damage.
3. If a new crankshaft and/or connecting rod is used,
select the proper bearing insert
in
accordance using
the combination table (Table F4) for the connecting
rod and the crankshaft marks
(Figs.
F55 and F56)
.
Table F4
Bearing Insert Selection
~
Crank-
Marking
0
No mark
shaft Marking
0
Black
Brown
P/N 92028-1050 P/N 92028-1051
No mark
Green
Black
P/N 92028-1049 P/N 92028-1050
A. Color Mark
B. Connecting Rod Mark (Circle)
A Crankshaft Mark (Circle)
4. Set the primary chain so that the crankshaft and
secondary shaft are timed (See Pg. 109).
5. Check to see that the main journal and big end
bear-
ing inserts are in place (Fig. F15)
.
6. Slip a 35 mm long hose onto each rod bolt before
installing the crankshaft. This keeps the bolt from
scratching the bearing surface.
7. Apply a molybdenum disulfide engine assembly
grease to the big end bolt threads and seating surface
of the bolt and the
nut.
Figner-tighten the nuts first,
then finger-tighten the bolts. Finally tighten the nuts
and bolts in the same sequence to 3.5 kg-m (25 ft-Ibs)
of torque.
CONNECTING RODS
Removal:
eRemove the
cylinder
block (Pg. 73).
eRemove the pistons and piston pins (Pg. 77).
eRemove the engine
(Pg.
96)
.
eSplit the crankcase (Pg. 98).
eMark the connecting rods and big end caps as to loca-
tion so that they can be reinstalled in their original
locations.
eRemove the nuts (6) and bolts (12), and pull off the
connecting rod big end caps and connecting rods.
~ ::dP::;e~~I:Sa:,a~~:; ;;~:~!Ot~et~;a~~~
shaft journals.
eMark the bearing inserts as to location so that they
can be reinstalled in their original
locations.
eRemove the connecting rod bearing insert halves from
the connecting
rod
big ends and the big end caps.
Installation Notes:
1. Be sure to replace the big end cap bolts (12) and
nuts (6) with new ones to get the correct
tightening
force.
~ ::~s:o :~~he~u~~t ~~~s f:i~~ren~~IO::~~~
ing. with extensive engine damage.
2.
When installing new connecting
rods,
use connecting
rods having the same weight mark.
This weight
111

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