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Crankshaft/connecting Rod Cleaning; Connecting Rod Bend/twist Inspection - Kawasaki EN500 Vulcan 500 LTD Service Manual

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8-14 CRANKSHAFT/TRANSMISSION
Crankshaft/Connecting Rods
Big End Cap [A]
Connecting Rod [B]
Weight Mark, Alphabet [C]
Diameter Mark [D]
Apply engine oil to the inner surface of the upper and
lower bearing inserts [A].
Apply a small amount of engine oil to the threads [B] and
seating surface [C] of the connecting rod big end cap nuts.
Tighten the cap nuts.
Torque - Connecting Rod Big End Cap Nuts: 36 N·m (3.7
kgf·m, 27 ft·lb)
Install the crankshaft (see Crankshaft Installation).

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/Twist Inspection

Measure the connecting rod bend.
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 100 mm (3.94 in.) long, and insert the arbor
[B] through the connecting rod small end.
On a surface plate, set the big-end arbor on V blocks [C].
With the connecting rod held vertical, 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 de-
termine 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:
0.2/100 mm (0.008/3.94 in.)

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   Also See for Kawasaki EN500 Vulcan 500 LTD

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Vulcan 500 ltd

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  • Ricardo Paluan Apr 27, 2016 01:22:
    Adquiri recentemen​te uma moto vulcan 500 ano 1995. Tenho o 37 anos e iniciante no mundo motociclis​ta. Entretanto​, em razão só tempo e idade da moto, não tenho o manual do proprietá​rio, sendo este indispens