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

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9-14 CRANKSHAFT/TRANSMISSION
Crankshaft and Connecting Rods
(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 includes
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 compressed
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 values
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 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
Connecting
Rod Assy
–
Bolt Length
before tightening
= Bolt Stretch
Usable Range of
Bolt Nut Connecting Rod
Bolt Stretch
Use the bolts Attached to 0.24 ∼ 0.36 mm
New attached to new con-rod (0.0094
new con-rod. New ∼ 0.0142 in.)
Used
Replace the
bolts with
new ones.
Used
New
0.20 ∼ 0.32 mm
(0.0079
∼ 0.0126 in.)