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Kawasaki KZ1300-A1 Quick Reference Manual Page 187

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MAINTENANCE--ENGINE
A.
Push
the big end.
Connecting rod bearing insert/journal wear
Bearing insert wear is measured using a plastigauge
(press gauge), which is inserted into the clearance to be
measured.
The plastigauge indicates the clearance by
the amount it is compressed and widened when the parts
are assembled.
NOTE: Do not turn the crankshaft during clearance
measurement.
-Split the crankcases, and remove the connecting rod
big end
caps.
-Wipe each journal and insert surface clean of oil.
-Cut strips of plastigauge to bearing insert width
.
Place
a strip on the connecting rod big end journal for each
connecting rod parallel to the crankshaft so that
plastigauge will be compressed between the bearing
insert and the connecting rod journal.
-Install the connecting rod big end caps, tightening
the nuts and bolts in the correct sequence to the
specified torque (Pg. 112).
-Remove the connecting rod big end cap, and measure
the plastigauge width to determine the bearing insertl
journal
wear.
A. Plastigauge
Table H41
Connecting Rod Bearing Insertl
Journal Clearance
Service Limit
0.10 mm
If the clearance exceeds the service limit, replace the
bearing inserts as follows:
-With a micrometer, measure the diameter of t\1e
crankshaft journals on which the connecting rods fit.
-Mark each flywheel in accordance with the journal
diameter (Table H42). If the measurement is less than
the service limit, replace the crankshaft. If the measure-
ment is less than the standard value, but is not under
the service limit; use bearing inserts painted green.
NOTE: Any mark already on the flywheel should not
be referred to during servicing.
A. Avoid the oil hole for measurement.
Table H42
Connecting Rod Journal Diameter
Marking
Standard
Service Limit
No mark
35.984-35.994 mm
35.97 mm
0
35.995-36.000 mm
-Put
the connecting rod big end caps on the rods and
tighten the nuts and bolts in the correct sequence to
the specified torque (Pg.112).
-Measure
the inside diameter, and mark each connect-
ing rod big end in accordance with the inside diameter
(Table H43).
NOTE: The mark already on the big end should almost
coincide with the measurement.
Table H43
Connecting Rod Big End Diameter
Marking
Standard
0
39.009-39.016 mm
No Mark
39.000-39.008 mm
-Select
the proper bearing insert in accordance with
the combination of the connecting rod and crankshaft
coding.
Table H44
Bearing Insert Selection
~
Marking
0
No Mark
Crank-
Shaft Marking
Black
Brown
0
PIN 92028-1050 PIN 92028-1051
Green
Black
No Mark
PIN 92028-1049 PIN 92028-1050
Table H45
Bearing Insert Thickness
Color
Standard
Green
1.485 -1.490 mm
Black
1.480 -1.485 mm
Brown
1.475-1.480 mm
187

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