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Discussion Starter · #1 ·
I have a 1982 Kawasaki KX80 i bought it for 100 dollars its a old race bike but it was seized the big end of the connecting rod was froze i have ordered a hot rods kit with (2) Thrust Washers, Piston pin Bearing, Big End Bearing, & Connecting Rod to fix it but i don't know the rod clearance and i don't what to have to much or not enough rod clearance.

ANY HELP IS APPRECIATED

here is the rod i got
Kawasaki KX 80 kx80 kdx80 Crank Connecting Rod Kit 82-:eBay Motors (item 140358758002 end time Nov-18-09 14:03:26 PST)

Here is some info on the bike

# 80 cc
# 2-Stroke, 1 Cylinder
# Piston Reed Valve
# 6-Speed, Return Shift
# Max. Horsepower:
# 19HP @ 11,500 rpm
# Spark Plug: NGK B9ES
# Engine No.: C1 ... KX080CE000001 -
# D1 ... KX080DE000001 -
# FrameNo.: C1 ...JKAKXWC17BA000001-
# D1 ... KX080D-000001 -
# Parts Catalog No.:
# C1 ... 99910-1147-01 plus 99910-1147-50R
# D1 ... 99910-1177-01 plus 99910-1177-50R
# Owner's & Service Manual No.: 99920-1724-01
 

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Obfuscation Engineer
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6,708 Posts
These usually come with a big end pin so radial clearance isn't a problem . Side clearance should be included in the kit .
 

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4,807 Posts
There are no adjustment provisions for a built up crankshaft. You put it together and everything should be within specs. as far as rod to journal clearance is concerned. Just as a note, this is an operation that most people cannot do at home. A dealer or machine shop operation only.
Also, if you have it this far apart, the crankcase seals should be replaced, too.
As a sidebar, if the crank was locked up, how is the piston, cylinder, rings, main bearings?
 

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WFO Enthusiast
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89 Posts
All you need is a press, a straight edge and a feeler gauge to rebuild the lower end. if you don't have a press, then its best to take it to a machine shop to have it done. If it is an ex-race bike, you should replace the piston and rings while its apart.
 

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Discussion Starter · #10 ·
well i made my own alignment pins and used a strait edge some marker and set the clearance t 3 thousands of a inch and pressed it to gether i replaced all seals gaskets and bearings it has no vibrations
 
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