Sealant - Kawasaki Bond: 92104-1064

NOTE

○Especially, apply a liquid gasket carefully so that it shall

be filled up on the grooves.

CAUTION

Do not apply liquid gasket around the crankshaft main bearing inserts, and oil passage holes.

○Do not apply liquid gasket to the oil passage [B].

 

 

• Fit the lower crankcase half to the upper crankcase half.

○Insert [A] the breather pipe [B] on the upper crankcase

half through the hole [C] on the lower crankcase half.

NOTE

○Make the application finish within 20 minutes when

the liquid gasket to the mating surface of the lower

crankcase half is applied.

○Moreover fit the case and tighten the case bolts just

after finishing the application of the liquid gasket.

○The M9 bolts [1 ~6] (see the next figure) have copper plated washers. Replace them with new ones.

• Apply molybdenum disulfide oil solution to both sides [A]

of the M9 bolts washers and the threads [B] of the M9

bolts.

 

 

• Apply molybdenum disulfide oil solution to flange [A] and the threads [B] of the M8 bolts which is tightening order is

[7 ~ 10] only (see the next figure).

 

 

• Tighten the lower crankcase bolts using the following steps.

○Following the sequence numbers on the lower crankcase

half, tighten the M9 bolts [1, 2] L= 113 mm (4.45 in.) with

washers.

Torque - Crankcase Bolts (M9): 44 N·m (4.5 kgf·m, 32 ft·lb)

○Tightenthe M9 bolts [3, 4] L= 83 mm (3.27 in.) with wash- ers.

Torque - Crankcase Bolts (M9): 44 N·m (4.5 kgf·m, 32 ft·lb)

○Tighten the M9 bolts [5, 6] L= 113 mm (4.45 in.) with washers.

Torque - Crankcase Bolts (M9): 44 N·m (4.5 kgf·m, 32 ft·lb)

○Tighten the M8 bolts [7 ~10].

Torque - Crankcase Bolts (M8): 35 N·m (3.6 kgf·m, 26 ft·lb)

○Tighten the M8 bolts [A] (Do not apply molybdenum oil solution).

Torque - Crankcase Bolts (M8): 27.5 N·m (2.8 kgf·m, 20 ft·lb)

○Tighten the M6 bolts [B].

Torque - Crankcase Bolts (M6): 19.6 N·m (2.0 kgf·m, 15 ft·lb)

• Tighten the upper crankcase bolts.

○The upper crankcase bolts have copper plated washers.

Replace them with new ones.

Torque - Upper Crankcase Bolts [A]: 27.5 N·m (2.8 kgf·m, 20 ft·lb)

• After tightening all crankcase bolts, check the following items.

○Crankshaft and balancer shafts turn freely.

 

Crankshaft Removal

• Split the crankcase (see Crankcase Splitting).

• Remove the crankshaft [A].

 

 

CAUTION

If the crankshaft, bearing inserts, or crankcase halves are replaced with new ones, select the bear- ing inserts and check clearance with a plastigage (press gauge) before assembling engine to be sure the correct bearing inserts are installed.

Crankshaft Installation

• Apply molybdenum disulfide oil solution to the crankshaft main bearing inserts.

○Align [A] the timing mark on the balancer gear [B] with the

timing mark on the balancer drive gear [C] of the crank-

shaft.

• Install the crankshaft with the camshaft chain [A] hanging on it.

 

Connecting Rod Removal

• Split the crankcase (see Crankcase Splitting).

• Remove the connecting rod nuts [A].

• Remove the crankshaft.

NOTE

○Mark and record the locations of the connecting rods

and their big end caps so that they can be reassembled

in their original positions.

CAUTION

Discard the connecting rod bolts. To prevent dam- age to the crankpin surfaces, do not allow the con- necting rod bolts to bump against the crankpins.

• Remove the connecting rods from the crankshaft.

 

Connecting Rod Installation

CAUTION

To minimize vibration, the connecting rods should have the same weight mark.

Big End Cap [A] Connecting Rod [B] Weight Mark, Alphabet [C]

Diameter Mark [D]: “○” or no mark

CAUTION

If the connecting rods, big end bearing inserts, or crankshaft are replaced with new ones, select the bearing insert and check clearance with a plasti- gage (press gauge) before assembling engine to be sure the correct bearing inserts are installed.

• Apply molybdenum disulfide grease [A] to the outer sur- face of the upper insert and the inner surface of the con-

necting rod big end.

• Apply molybdenum disulfide oil solution [B] to the inner surfaces of upper and lower bearing inserts.

○The molybdenum disulfide oil solution is a mixture of en-

gine oil and molybdenum disulfide grease with a weight

ratio (10: 1).

○Do not apply any grease or oil [C] to the cap inside and

cap insert outside.

○Install the inserts so that their nails [D] are on the same

side and fit them into the recess of the connecting rod and

CAUTION

Wrong application of oil and grease could cause bearing damage.

cap.

○When installing the inserts [A], be careful not to damage the insert surface with the edge of the connecting rod [B] or the cap [C]. One way to install inserts is as follows.

Installation [D] to Cap

Installation [E] to Connecting Rod Push [F]

Spare Dowel Pin [G] Connecting Rod Bolts [H]

• Install the cap on the connecting rod, aligning the weight

and diameter marks.

• Remove debris and clean the surface of inserts.

• Apply molybdenum disulfide oil solution [MO] to the

threads and seating surfaces of the big end nuts and

bolts.

 

 

• Install the crankshaft (see Crankshaft Installation).

• Install each connecting rod on its original crankpin.

NOTE

○Install each connecting rod so that its oil jet [A] faces the

exhaust side (the front [B]) (see Engine Oil Flow Chart

in the Engine Lubrication System chapter).

○The connecting rod big end is bolted using the “plastic region fastening method”.

○This method precisely achieves the needed clamping

force without exceeding it unnecessarily, allowing the

use of thinner, lighter bolts further decreasing connecting rod weight.

○There are two types of the plastic region fastening. One is

a bolt length measurement method and other is a rotation

CAUTION

The connecting rod bolts are designed to stretch when tightened. Never reuse the connecting rod bolts. See the table below for correct bolt and nut usage.

CAUTION

Be careful not to overtighten the nuts. The bolts must be positioned on the seating surface correctly to prevent the bolt heads from hitting the crankcase.

angle method. Observe one of the following two, but the bolt length measurement method is preferable because this is a more reliable way to tighten the big end nuts.

 

 

(1) Bolt Length Measurement Method

• Be sure to clean the bolts, nuts, and connecting rods thoroughly with a high-flash point solvent, because the

new connecting rods, bolts, and nuts are treated with an anti-rust solution.

WARNING

Clean the bolts, nuts, and connecting rods in a well -ventilated area, and take care that there is no spark or flame anywhere near the working area. This in- cludes any appliance with a pilot light. Because of the danger of highly flammable liquids, do not use gasoline or low-flash point solvents to clean them.

CAUTION

Immediately dry the bolts and nuts with com- pressed air after cleaning. Clean and dry the bolts and nuts completely.

 

 

• Install new bolts in reused connecting rods.

• Dent both bolt head and bolt tip with a punch as shown.

• Before tightening, use a point micrometer [A] to measure

the length of new connecting rod bolts and record the val-

ues to find the bolt stretch. Connecting Rod [B]

Mark here with a punch [C]. Nuts [D]

Fit micrometer pins into punch marks [E].

• Apply a small amount of molybdenum disulfide oil solution to the following.

Threads of Nuts and Bolts

Seating Surfaces of Nuts and Con-rods

• Tighten the big end nuts until the bolt elongation reaches the length specified in the table.

• Check the length [F] of the connecting rod bolts.

If the stretch is more than the usable range, the bolt has

stretched too much. An overelongated bolt may break in use.

Bolt Length

after tightening –

Bolt Length

before tightening = Bolt Stretch

 

Connect- ing Rod Assy	Bolt	Nut	Usable Range of Connecting Rod Bolt Stretch
New	Use the bolts attached to new con-rod.	Attached to new con-rod	0.24 ~ 0.36 mm (0.0094 ~ 0.0142 in.)
New
Used	Replace the bolts with new ones.	Used	0.20 ~ 0.32 mm (0.0079 ~ 0.0126 in.)
New

 

(2) Rotation Angle Method

If you don’t have a point micrometer, you may tighten the nuts using the “Rotation Angle Method”.

• Be sure to clean the bolts and nuts thoroughly with a high

-flash point solvent, because the new bolts and nuts are

treated with an anti-rust solution.

WARNING

Clean the bolts and nuts in a well-ventilated area, and take care that there is no spark or flame any- where near the working area. This includes any ap- pliance with a pilot light. Because of the danger or highly flammable liquids, do not use gasoline or low-flash point solvents to clean them.

CAUTION

Immediately dry the bolts and nuts with com- pressed air after cleaning. Clean and dry the bolts and nuts completely.

 

 

• Install new bolts in reused connecting rods.

• Apply a small amount of molybdenum disulfide oil solution

to the following.

Threads [A] of Nuts and Bolts

Seating Surfaces [B] of Nuts and Con-rods

 

 

• First, tighten the nuts to the specified torque. See the table below.

• Next, tighten the nuts 120° ±5°.

○Mark [A] the connecting rod big end caps and nuts so that

nuts can be turned 120° [B] properly.

 

Connect- ing Rod Assy	Bolt	Nut	Torque + Angle N·m (kgf·m, ft·lb)
New	Use the bolts attached to new con-rod.	Attached to new con-rod	18 (1.8, 13.0) + 120°
New	20 (2.0, 14.5) + 120°
Used	Replace the bolts with new ones.	Used	24 (2.4, 17.4) + 120°
New	25 (2.6, 18.8) + 120°

 

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

• 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 block [C].

• With the connecting rod held vertically, 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 determine the amount of connecting rod bend. If connecting rod bend exceeds the service limit, the con- necting rod must be replaced.

Connecting Rod Bend