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

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9-18 CRANKSHAFT/TRANSMISSION
Crankshaft and Connecting Rods
Connecting Rod Big End Inside Diameter Marks
None 38.000mm ∼ 38.008mm (1.4961 ∼ 1.4964 in.)
38.009 ∼ 38.016 mm (1.4964 ∼ 1.4967 in.)
BigEndCap[A]
Connecting Rod [B]
Weight Mark, Alphabet [C]
Diameter Mark (Around Weight Mark) [D]: “
mark
”orno
• Select the proper bearing insert [A] in accordance with the
combination of the connecting rod and crankshaft coding.
Size Color [B]
Con-rod Big End Crankpin Bearing Insert
Inside Diameter Diameter
Marking Marking Size Color Part Number
None Brown 92139–1110
None
None
Black 92139–1109
None Blue 92139–1108
• Install the new inserts in the connecting rod and check
insert/crankpin clearance with the plastigage.
Crankshaft Side Clearance
• Insert a thickness gauge [A] between the crankcase main
bearing and the crank web at the No. 2 journal [B] to
determine clearance.
If the clearance exceeds the service limit, replace the
crankcase halves as a set.
NOTE
○The upper and lower crankcase halves are machined
at the factory in the assembled state, so the crankcase
halves must be replaced as a set.
Crankshaft Side Clearance
Standard: 0.05 ∼ 0.20 mm (0.0020 ∼ 0.0079 in.)
Service Limit: 0.40 mm (0.0157 in.)
Crankshaft Runout
• Measure the crankshaft runout.
If the measurement exceeds the service limit, replace the
crankshaft.
Crankshaft Runout
Standard: TIR 0.02 mm (0.0008 in.) or less
Service Limit: TIR 0.05 mm (0.0020 in.)