Kawasaki J300 - Service manual > Crankcase/Crankshaft

Exploded View

EO: Apply engine oil.
G: Apply grease.
L: Apply a non-permanent locking agent.
LG: Apply liquid gasket.

Specifications

Special Tools and Sealant

Bearing Driver Set: 57001-1129

Flywheel Holder: 57001-1313

Liquid Gasket, TB1215: 92104-1065

Crankcase

Crankcase Splitting

• Remove the engine (see Engine Removal in the Engine Removal/Installation chapter).
• Set the engine on a clean surface and hold the engine steady while parts are being removed.
• Remove:
  Cylinder (see Cylinder Removal in the Engine Top End chapter)
  Piston (see Piston Removal in the Engine Top End chapter)
  Clutch/Driven Pulley (see Clutch/Driven Pulley Removal in the Converter System chapter)
  Starter Motor Clutch Gear and Starter Idle Gear (see Starter Motor Clutch Gear and Starter Idle Gear Removal)
  Oil Pump (see Oil Pump Removal in the Engine Lubrication System chapter)
  Camshaft Chain (see Camshaft Chain Removal in the Engine Top End chapter)
  Oil Screens (see Oil Screen Removal in the Engine Lubrication System chapter)
  Oil Pressure Relief Valve (see Oil Pressure Relief Valve Removal in the Engine Lubrication System chapter)
  Oil Pressure Switch (see Oil Pressure Switch Removal in the Engine Lubrication System chapter)
• Remove:
  Crankcase Bolts [A]
  Guide [B]

If the crankcase does not split easily, tap the crankcase ribs [A] lightly with a plastic mallet.

• Take care not to damage the crankcase.

• Remove the right crankcase.

NOTE

• Never use a driver to knock the crankcase mating surfaces apart.

 

• Remove the crankshaft [A] from the left crankcase.

NOTE

• Avoid damaging the bearing.
• Avoid damaging the crankcase mating surfaces.

Crankcase Assembly

WARNING Gasoline and low flash-point solvents can be flammable and/or explosive and cause severe burns. Clean the crankcase in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area; this includes any appliance with a pilot light. Do not use gasoline or a low flash-point solvent to clean the crankcase.

• If the crankshaft bearing is damaged, replace it (see Crankshaft Bearing Replacement).
• Chip off the old gasket from the mating surfaces of the crankcase halves, and clean off the crankcase and crankshaft with a high flash-point solvent. After cleaning, apply engine oil to the bearings.
• Replace the oil seal of the left crankcase with a new one.
• Install the oil seal with the bearing driver set.

  Special Tool - Bearing Driver Set: 57001-1129

• Apply grease to the oil seal lips.
• Be sure to replace any bearings removed with new ones (see Crankshaft Bearing Replacement).
• Install the crankshaft [A] to the left crankcase.

NOTE

• Avoid damaging the oil seal and bearing.
• Avoid damaging the crankcase mating surfaces.

• Check to see that the crankcase dowel pins [B] are in place.
• Replace the O-ring [C] with a new one.
• With a high flash-point solvent, clean off the mating surfaces of the crankcase halves and wipe dry.
• Apply liquid gasket to the mating surface of the left crank case.

  Sealant - Liquid Gasket, TB1215: 92104-1065

• Install the left crankcase. -Tighten the crankcase bolts together with the guide.

  Torque - Crankcase Bolts: 9.8 N*m (1.0 kgf*m, 87 in*lb)

Crankshaft Bearing Replacement

• Remove the crankshaft bearing [A].

  Special Tool - Bearing Driver Set [B]: 57001-1129

• Replace the crankshaft bearings with new ones.
• Select the new bearing, refer to the following.

Crankshaft Bearing Color [A]

• Install the crankshaft bearing.

  Special Tool - Bearing Driver Set: 57001-1129

Crankshaft, Connecting Rod

Crankshaft Removal

• Refer to the Crankcase Splitting.

Crankshaft Installation

• Refer to the Crankcase Assembly.

Crankshaft Disassembly

If the crankshaft is damaged, replace it as a set. Not for sale to each part of the crankshaft.

Connecting Rod Big End Radial Clearance Inspection

• Set the crankshaft on V blocks [A] and place a dial gauge [B] against the connecting rod big end [C].
• Push [D] the connecting rod first towards the gauge and then in the opposite direction. The difference between the two gauge readings is the radial clearance.

  If the radial clearance exceeds the service limit, replace the crankshaft assembly.

Connecting Rod Big End Radial Clearance
 Standard: 0 - 0.008 mm (0 - 0.0003 in.)
 Service Limit: 0.05 mm (0.002 in.)

Connecting Rod Big End Seizure Inspection

• In case of seizure, replace the crankshaft assembly.

Connecting Rod Big End Side Clearance Inspection

• Measure the side clearance of the connecting rod with a thickness gauge [A].

  If the clearance exceeds the service limit, replace the crankshaft assembly.

Connecting Rod Big End Side Clearance
 Standard: 0.15 - 0.35 mm (0.0059 - 0.0138 in.)
 Service Limit: 0.6 mm (0.024 in.)

Crankshaft Runout Inspection

• Set the crankshaft [A] on V blocks, and place a dial gauge against the points indicated.
• Turn the crankshaft slowly. The maximum difference in gauge readings is the crankshaft runout.

  If the runout at either point exceeds the service limit, replace the crankshaft assembly.

Crankshaft Runout
 Standard: TIR 0.03 mm (0.0012 in.) or less
 Service Limit: TIR 0.1 mm (0.004 in.)

Starter Motor Clutch

Starter Motor Clutch Removal

• Refer to the Starter Motor Clutch Disassembly.

Starter Motor Clutch Installation

• Refer to the Starter Motor Clutch Assembly.

Starter Motor Clutch Inspection

• Remove:
  Alternator Cover (see Alternator Cover Removal in the Electrical System chapter)
  Starter Motor (see Starter Motor Removal in the Electrical System chapter)
• Turn the starter motor clutch gear [A] by hand. The starter clutch gear should turn counterclockwise [B] freely, but should not turn clockwise [C].
  If the starter motor clutch does not operate as it should or if it makes noise, go to the next step.
• Disassemble the starter motor clutch, and visually inspect the clutch parts.
  If there is any worn or damaged part, replace it.

NOTE

• Examine the starter motor clutch gear as well. Replace it if it is worn or damaged.

Starter Motor Clutch Disassembly

• Remove the alternator rotor (see Alternator Rotor Removal in the Electrical System chapter).
• Holding the alternator rotor by flywheel holder [A], remove the starter motor clutch bolts [B].

  Special Tool - Flywheel Holder: 57001-1313

NOTICE Do not hold the rotor at pick-up portion with the flywheel holder.

• Remove:
  Starter Motor Clutch Housing [A]
  Starter Motor Clutch [B]

Starter Motor Clutch Assembly

• Install the starter clutch and the starter clutch housing to the alternator rotor.
• Holding the alternator rotor by flywheel holder.

  Special Tool - Flywheel Holder: 57001-1313

• Apply a non-permanent locking agent to the threads of the starter motor clutch bolts and tighten them.

  Torque - Starter Motor Clutch Bolts: 20 N*m (2.0 kgf*m, 15 ft*lb)

Starter Motor Clutch Gear and Starter Idle Gear Removal

• Remove:
  Alternator Rotor (see Alternator Rotor Removal in the Electrical System chapter)
  Starter Motor Clutch Gear [A]
  Shaft [B]
  Starter Idle Gear [C]

Starter Motor Clutch Gear and Starter Idle Gear Installation

• Installation is the reverse of removal.

See also: