Kawasaki Z1000 - ZR1000 2003-04 Service Manual - Small Engine ...

Connecting Rod Bolt Stretch:
(Usable Range)
New connecting rod 0.24 ∼ 0.36 mm ---
(0.0094 ∼ 0.0142 in.)
Used connecting rod 0.20 ∼ 0.32 mm ---
(0.0079 ∼ 0.0126 in.)
Crankshaft side clearance 0.05 ∼ 0.20 mm 0.40 mm
(0.0020 ∼ 0.0079 in.) (0.0157 in.)
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9-6 CRANKSHAFT/TRANSMISSION
Specifications
Item Standard Service Limit
Crankshaft, Connecting Rods:
Connecting rod bend --- TIR 0.2/100 mm
(0.008/3.94 in.)
Connecting rod twist --- TIR 0.2/100 mm
(0.008/3.94 in.)
Connecting rod big end side clearance 0.13 ∼ 0.38 mm 0.58 mm
(0.0051 ∼ 0.0150 in.) (0.023 in.)
Connecting rod big end bearing insert/crankpin 0.041 ∼ 0.071 mm 0.11 mm
clearance (0.0016 ∼ 0.0028 in.) (0.0043 in.)
Crankpin diameter: 34.984 ∼ 35.000 mm 34.97 mm
(1.3773 ∼ 1.3780 in.) (1.3768 in.)
Marking None 34.984 ∼ 34.992 mm - --
(1.3773 ∼ 1.3776 in.)
34.993 ∼ 35.000 mm ---
(1.3777 ∼ 1.3780 in.)
Connecting rod big end inside diameter: 38.000 ∼ 38.016 mm ---
(1.4961 ∼ 1.4967 in.)
Marking None 38.000 ∼ 38.008 mm ---
(1.4961 ∼ 1.4964 in.)
38.009 ∼ 38.016 mm ---
(1.4964 ∼ 1.4967 in.)
Connecting rod big end bearing insert thickness:
Brown 1.475 ∼ 1.480 mm ---
(0.05807 ∼ 0.05827 in.)
Black 1.480 ∼ 1.485 mm ---
(0.05827 ∼ 0.05846 in.)
Blue 1.485 ∼ 1.490 mm ---
(0.05846 ∼ 0.05866 in.)
Connecting rod big end bearing insert selection:
Con-rod Big End Crankpin Bearing Insert
Bore Diameter Diameter
Marking Marking Size Color Part Number
None Brown 92139–1110
None None Black 92139–1109
None Blue 92139–1108