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Kawasaki KZ1300-A1 Quick Reference Manual Page 188

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MAINTENANCE--ENGINE
Connecting rod
bend,
twist
eRemove
the connecting rod big end bearing inserts and
install the connecting rod big end
cap.
eSelect
an arbor of the same diameter as the connecting
rod big end and of optional length, and insert it through
the big end of the connecting rod.
eSelect
an arbor of the same diameter as the
piston
pin
and of optional length, and insert it through the small
end of the connecting rod.
eon
a surface plate, set the big-end arbor on
V
blocks
so that the connecting rod is perpendicular to the sur-
face plate as shown in the figure
.
eUsing
a height gauge or dial gauge, measure the differ-
ence in the height of the small-end arbor above the
surface plate over a 100 mm length to determine the
amount the connecting rod is
bent.
elf
the measurement exceeds the service limit, replace
the connecting rod.
Connecting Rod Bend Measurement
Table
H46
Connecting Rod Bend/100
mm
Service Limit
0.2 mm
eSwing
the connecting rod 90
0
to one side and support
it parallel to the surface
plate
as
shown
in the figure.
eMeasure
the difference in the height of the small-end
arbor above the surface plate over a 100 mm length to
determine the amount the connecting rod is twisted.
elf
the measurement exceeds the service limit replace
the connecting rod.
Connecting Rod Twist Measurement
(H68)
Table
H47
Connecting Rod Twist/100 mm
Crankshaft
runout
eSet
the crankshaft in a flywheel alignment jig or on
V
blocks, and place a dial gauge against each crankshaft
journal.
eTurn
the crankshaft slowly. The maximum difference
in
gauge readings is the crankshaft runout.
elf
the measurement exceeds the service limit, replace
the crankshaft.
Table
H48
Crankshaft Runout
Service Limit
0.08 mm
Crankshaft bearing insert/journal wear
eSplit
the crankcase, and clean off the mating surfaces
of the crankcase
halves.
-Cut
strips of plastigauge to bearing insert width. Place
a strip on each journal parallel to the crankshaft so
the plastigauge will be compressed between the bearing
insert and the crankshaft journal.
elnstall
the lower crankcase half without turning the
crankshaft, and tighten the bolts in the correct se-
quence to the specified amount of torque (Pg. 101).
eRemove
the lower crankcase half (making sure that
the crankshaft
does
not turn at any time), and mea-
sure the
plastigauge
width to
determine
the
bearing
insert/journal
wear.
elf
any clearance exceeds the service limit, replace
all bearing inserts (14), and check the crankshaft
journals.
Service Limit
0.2
mm
A. Plastigauge
188

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