You ask I will try to answer
I drag race a street legal turbo ZRX1100, and have had some problems with
rod bearings. The cranks have been blueprinted by Falicon, and I run Carrillo
rods. Also I'm using a Muzzy dry sump pan, and oil starvation is not the
problem. I have been setting the clearance using the specs from the manual
- .042-.070mm, but I just ran across an old post of yours where you listed
your clearance a bit bigger than this. Can you offer any advice?
Rod bearing seizure is always a lack of lubrication at the failed bearing.
First thing you want to look at is the main bearings and how they are living. If your main bearings are in good shape and the rod bearing have damage, then it would be safe to say that oil does make as far as the mains but for some reason it isn't getting to the rods.
If your failure is at both the main and rod bearings there has been no oil at either.
In the first instance of rod bearing and not main bearing failure the reason can usually be tracked down to oil not making it into the rod journal this is usually from excessive engine rpm. As the crankshaft turns at a high speed the oil hole can actually travel fast enough not to allow the get in the journal. The high surface speed of the oil hole will cause the oil to begin to cavitate over the opening and only air and frothed up oil will get to the rod. Then you have a metal to metal contact, the bearing will soon fail.
The remedy for this is not running as high of engine rpm in excess of engine red-line, you can raise that RPM by modifying the main bearing holes to pick- up more oil as the crank is spinning.
If your failure is of the second type where both main and rod bearings have failed you need to check your oiling system for blockage or internal leakage. Also this will happen when a motor is revved high while the oil is cold and doesn't freely flow throughout the motor. A liberal warm-up time is recommended to help avoid this kind of failure. Also use only a Kawasaki brand oil filter some time other brands don't have the same flow rate as the OE filter. However I use a external filter with a 50 micron screen on the ZX11 Funnybike.
I recommend running your clearances near .003" you should also shim your bypass valve to raise oil pressure, also for race use you can significantly raise oil pressure to the crankshaft by restricting the oil pressure to the cylinder head by modifying the banjo bolt that feeds the head and cams. I also use Mobil 1 15w50, when its cold I will go with a lighter weight oil.
I also use only new crankshafts, re-welds have proven not to have the reliability as the new stock parts.
There are allot of small things you can do for you oiling system, being sure that oil is able to flow as freely and un-restricted as possible is the most important.