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I'm rebuilding my own crank from a '92
Rod clearance was .058 before I pressed it apart which was only .003 out of spec and far from the service limit.
My problem is with the Wiseco rod kit I bought. The rod big end width specs out the same as the old rod but the thrust washers are .005 thinner.
If I press the crank back together to the same width it was before the rebuild I'm going to end up with .068 clearance and be .013 out of spec with the new rod.
Which is more important to maintain. Rod side clearance or crank width?
Anyone have the correct spec for crank width on the 250?

Can you just get OEM washers??

If you press the two halves inward to take up the space, won't it barely be narower overall?? Maybe it won't be a problem, but I am just wondering.

What tonnage of press was required to do the job? Thank you.

I don't know if I can get just the washers. This pisses me off...
Further checking shows the new washers are indeed .005 thinner than spec'ed in the Kawi parts fiche.
Took a 30 ton to press it apart.

92026-1241, superseeded to 92026-1500, $3.10 each at Ron Ayers.

I am guessing stock is 1.6mm. Part info is : SPACER,24X42X1.6



Thank you for the information on the press. I had been told 25 tons in the past (for a 250 crank).

Thanks Jason!!
1.6 is stock...yes

If you don't mind me asking, what equipment do you have for crank rebuilding? That is one area I never tried to get into.

Press, V-block set with twin deflection guages, brass hammer, dial calipers and a micrometer set will do it. Probably not worth buying just for your bike but I already have the stuff from my drag racing hobby.

Ron Ayers won't accept my Canada postal code for some reason.
Anyone else from Can buy there?

Thanks for the information.

Hopefully, you can order the OEM parts from a Canadian Kawasaki dealer.

You only buy parts form a Canadian dealer if you want to be bent over

Aw, come on. It may be $5??

Probably more like $25...really

Talked to Wiseco and they say the rod kit comes with 1.5 washers and he's going to check with their engineers as to why when the factory specs 1.6
Says he's never heard this before in 10 years of selling these rods kits.
Maybe I'm too picky...

I really don't think that little bit is going to matter. Your flywheel and clutch basket will still bolt on with no problem. The important parts are just to make sure the rod side clearance is correct and that the crank is centered in the case halves.

Jason wrote:Aw, come on. It may be $5??

Kroynon wrote:Probably more like $25...really

I don't even ask a Canadian dealer anymore,they're prices are crazy compared to US prices.Enough to pay the extra shipping.