Kawasaki KLE500 (2004) [202/401] 16 crankshaft transmission

9-16 CRANKSHAFT/TRANSMISSION

Crankshaft/Connecting Rods

Crankshaft Removal

•

Split the crankcase (see Crankcase Splitting).

•

Remove the clutch housing and the primary chain.

•

Remove the crankshaft with the camshaft chain and pri-

mary chain.

Crankshaft Installation

CAUTION

If the crankshaft, bearing inserts or crankcase

halves are replaced with new ones, select the bear-

ing inserts and check clearance with plastigage

before assembling engine to be sure the correct

bearing inserts are installed.

•

Apply molybdenum disulfide oil to the crankshaft bearing

inserts.

•

Install the camshaft and primary chains on the crankshaft.

•

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

the timing mark [B] on the balancer drive gear [C] of the

crankshaft.

•

Assemble the crankcase (see Crankcase Assembly).

Connecting Rod Removal

•

Remove the crankshaft (see C rankshaft Removal).

NOTE

○

Mark and record locations of the connecting rods and

their big end caps so that they can be reassembled in

their original positions.

•

Remove the connecting rod big end cap nuts, and take off

the rod and cap with the bearing inserts from the crank-

shaft.

CAUTION

To prevent damage to the crankpin surfaces, do not

allow the big end cap bolts to bump against them.