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Crankshaft/Connecting Rods
Remove the connecting rod big end caps, and mea-
sure the plastigage width [A] to determine the bearing
insert/crankpin [B] clearance.
Connecting Rod Big End Bearing Insert/Crankpin
0.043 ∼ 0.073 mm (0.0017 ∼ 0.0029 in.)
Service Limit: 0.10 mm (0.04 in.)
If the clearance is within the standard, no bearing insert
replacement is required.
If the clearance is between 0.066 mm (0.0026 in.)
and the service limit 0.10 mm (0.04 in.), replace the
bearing inserts [A] with inserts painted blue [B] Check in-
sert/crankpin clearance with a plastigage. The clearance
may exceed the standard slightly, but it must not be less
than the minimum in order to avoid bearing seizure.
If the clearance exceeds the service limit, measure the
diameter of the crankpins.
Crankpin Diameter
37.984 ∼ 38.000 mm (1.4954 ∼ 1.4961 in.)
Service Limit: 37.97 mm (1.495 in.)
If any crankpin has worn past the service limit, replace the
crankshaft with a new one.
If the measured crankpin diameters are not less than the
service limit, but do not coincide with the original diameter
markings on the crankshaft, write new marks on it.
Crankpin Diameter Marks
37.984 ∼ 37.994 mm (1.4954 ∼ 1.4958 in.)
37.995 ∼ 38.000 mm (1.4959 ∼ 1.4961 in.)
Crankpin Diameter Marks, "
Put the connecting rod big end caps on the rods and
tighten the nuts to the specified torque.
Torque - Connecting Rod Big End Cap Nuts: 36 N·m (3.7
kgf·m, 27 ft·lb)
Measure the bore diameter, and mark each connecting
rod big end in accordance with the bore diameter.
" mark or no mark.


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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