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

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Crankshaft, Connecting Rod
Check the following items are within specifications after
the crankshaft assembly.
Connecting Rod Radial Clearance (see Connecting Rod
Big End Radial Clearance Inspection)
Connecting Rod Side Clearance (see Connecting Rod
Big End Side Clearance Inspection)
Crankshaft Runout (see Crankshaft Runout Inspection)

Connecting Rod Big End Seizure Inspection

In the case of serious seizure with damaged flywheels,
the crankshaft must be replaced.
In the case of less serious damage, disassemble the
crankshaft and replace the crankpin, needle bearing,
side washers, and connecting rod.
Connecting Rod Big End Radial Clearance
Inspection
Set the crankshaft in flywheel alignment jig or on a V
block, 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 crank-
shaft should be either replaced or disassembled and the
crankpin, needle bearing, and connecting rod big end ex-
amined for wear.
Connecting Rod Big End Radial Clearance
0.005 ∼ 0.025 mm (0.0002 ∼ 0.0010 in.)
Standard:
Service Limit: 0.07 mm (0.0028 in.)
Connecting Rod Big End Side Clearance
Inspection
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
0.1 ∼ 0.2 mm (0.004 ∼ 0.008 in.)
Standard:
Service Limit: 0.4 mm (0.016 in.)

Crankshaft Runout Inspection

Set the crankshaft in a flywheel alignment jig or on V
blocks, and place a dial gauge [A] against the points indi-
cated.
Measurement Point [B]: 8 mm (0.315 in.)
Turn the crankshaft slowly. The maximum difference in
gauge readings is the crankshaft runout.
Crankshaft Runout
Standard:
TIR 0.03 mm (0.001 in.) or less
Service Limit: TIR 0.08 mm (0.003 in.)
CRANKSHAFT/TRANSMISSION 8-13

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