E-Z-GO Engine, Shop Rebuild Manual, Page: 45 / 100

ENGINE MEASUREMENTS
Page C-15
Kawasaki Engine Shop Rebuild Manual
G. Measure connecting rod twist.
H.
With the big-end arbor still on the V blocks [A], hold
the connecting rod horizontally. Use a height gauge
[B] to measure the amount that the small end arbor
varies from being parallel with the surface plate over
a 100 mm length of the arbor to determine the
amount of connecting rod twist.
I. If connecting rod twist exceeds the service limit, the
connecting rod must be replaced.
Connecting Rod Twist
Service Limit: 0.15/100 mm (0.006/3.94 in.)
Measure Connecting Rod Big End/Crankpin
Width Wear
A.
Measure the connecting rod big end width [A] with a
micrometer or dial caliper.
B. If the measurement is less than the service limit,
replace the connecting rod.
Connecting Rod Big End Width
Standard: 27.4 ~ 27.7 mm (1.08 ~ 1.09 in.)
Service Limit: 27.0 mm (1.06 in.)
C.
Measure the crankpin width [A] with a dial caliper.
D. If the crankpin width is more than the service limit,
replace the crankshaft.
Crankpin Width
Standard: 28.0 ~ 28.2 mm (1.10 ~ 1.11 in.)
Service Limit: 28.4 mm (1.12 in.)
Measure Connecting Rod Big End Bearing/
Crankpin Wear
A. Apply a thin film of oil on the thread of the cap bolts.
B. Install the cap bolts and tighten the bolts to the speci-
fied torque (see Install Piston in Section D).
C.
Measure the inside diameter [A] of big end at several
points with a telescoping gauge or inside micrometer.
D. If the inside diameter is more than the service limit,
replace the connecting rod with a new one.
Connecting Rod Big End Inside Diameter
Standard: 43.004 ~ 43.015 mm (1.6931 ~ 1.6935 in.)
Service Limit: 43.04 mm (1.694 in.)