Kawasaki KLE500 (2004) [207/401] Crankshaft transmission 9 21
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Kawasaki KLE500 (2004) [207/401] Crankshaft transmission 9 21

Kawasaki KLE500 (2004) [207/401] Crankshaft transmission 9 21
CRANKSHAFT/TRANSMISSION 9-21
Crankshaft/Connecting Rods
○
Install the lower crankcase half, and tighten the case bolts
to the specified torque.
Torque - Crankcase 8 mm Bolts: 27 N·m (2.8 kgf·m, 20 ft·lb)
Crankcase 6 mm Bolts: 12 N·m (1.2 kgf·m, 104
in·lb)
NOTE
○
Do not turn the crankshaft during clearance measure-
ment.
○
Remove the lower crankcase half and measure the plas-
tigage width [A] to determine the bearing insert/journal [B]
clearance.
Crankshaft Main Bearing Insert/Journal Clearance
Standard: 0.020 ∼ 0.044 mm (0.0008 ∼ 0.0017 in.)
Service Limit: 0.08 mm (0.0032 in.)
If the clearance is within the standard, no bearing insert
replacement is required.
If the clearance is between 0.044 mm (0.0017 in.) and the
service limit 0.08 mm (0.0032 in.), replace the bearing in-
serts [A] with inserts painted blue [B] Check insert/journal
clearance with a plastigage. The clearance may exceed
the standard slightly, but it must not be less than the min-
imum in order to avoid bearing s eizure.
If the c learance exceeds the service limit, measure the
diameter of the crankshaft main journal.
Crankshaft Main Journal Diameter
Standard: 35.984 ∼ 36.000 mm (1.4167 ∼ 1.4173 in.)
Service Li m it: 35.96 mm (1 .4 15 7 in.)
If any journal has worn past the service limit, replace the
crankshaft with a new one.
If the measured journal diameters are not less than the
service limit, but do not coincide with the original diameter
markings on the crankshaft, write a new mark on it.
Crankshaft Main Journal Diameter Marks
None: 35.984 ∼ 35.992 mm (1.4167 ∼ 1.4170 in.)
1: 35.993 ∼ 36.000 mm (1.4170 ∼ 1.4173 in.)
□: Crankshaft Main Journal Diameter Marks, "1" mark or
no mark.
•
Put the lower crankcase half on the upper crankcase half
without bearing inserts, and tighten the case bolts to the
specified torque and sequence (see Crankcase Assem-
bly).
•
Measure the crankcase main bearing bore diameter, and
mark the upper crankcase half in accordance with the
bore diameter.
NOTE
○
The mark already on the upper crankcase half should
almost coincide with the measurement.

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