Kawasaki Ninja Service Manual: Crankcase Halves Assembly

Kawasaki Ninja Service Manual / Crankshaft/Transmission / Crankcase / Crankcase Assembly / Crankcase Halves Assembly

Sealant - Liquid Gasket, TB1216B [A]: 92104-1064 Liquid Gasket, TB1207B [B]: 92104-2068

NOTE

NOTICE

Do not apply liquid gasket around the crankshaft main bearing inserts and oil passage.

Crankcase Halves Assembly


NOTE

Install the drive shaft bearing [A].

Special Tool - Bearing Driver Set: 57001-1129

Crankcase Halves Assembly


Face the oil seal side of the bearing to the bottom.

Crankcase Halves Assembly


L = 113 mm (4.45 in.) [A] L = 100 mm (3.94 in.) [B]

Tighten M9 bolts by following the sequence numbers [1
10].

Torque - Lower Crankcase Bolts (M9): 45 N·m (4.6 kgf·m, 33 ft·lb)

Crankcase Halves Assembly


Install the M7 bolts.

L = 50 mm (2.0 in.) [A] L = 45 mm (1.8 in.) [B] Tighten:

Torque - Lower Crankcase Bolts (M7): 20 N·m (2.0 kgf·m, 15 ft·lb)

Crankcase Halves Assembly


Replace the M6 bolt washers with new ones.

Install the M6 bolts.

L = 60 mm (2.4 in.) [A] (With Washer) L = 45 mm (1.8 in.) [B] L = 40 mm (1.6 in.) [C]

Install the clamp [D] and washer [E] as shown in the figure.

Tighten:

Torque - Lower Crankcase Bolts (M6): 12 N·m (1.2 kgf·m, 106 in·lb)

Crankcase Halves Assembly


Crankcase Halves Assembly


Replace the M8 bolt washers with new ones.

Install the M8 bolts [A] and washers.

Install the M7 bolt [B].

Tighten:

Torque - Upper Crankcase Bolts (M8): 27 N·m (2.8 kgf·m, 20 ft·lb) Upper Crankcase Bolt (M7): 20 N·m (2.0 kgf·m, 15 ft·lb)

Wipe up the liquid gasket that seeps out around the crankcase mating surface.

Crankshaft turns freely.

Drive Shaft Bearing Holder [A] Output Shaft Bearing Holder [B]

Crankcase Halves Assembly


Turn the flat side [C] of the holders to inside.

Lower Crankcase Assembly
Install the ball bearing [A] and the oil level inspection window [B] until they are bottomed Apply soap and water solution to the oil level inspection window before installation. Install ...

Crankshaft and Connecting Rods
...

Other materials:

Location of parts
Clutch Lever Left Handlebar Switches Rebound Damping Force Adjuster (Front Fork) Compression damping force adjuster (Front Fork) Meter Instruments Brake Fluid Reservoir (Front) Right Handlebar Switches Front Brake Lever Throttle Grip Ignition Switch/Steering Lock Elect ...

Oxygen Sensor Heater Power Source Voltage Inspection
NOTE Be sure the battery is fully charged. Turn the ignition switch to OFF. Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter). Disconnect the oxygen sensor lead connector and connect the measuring adapter [A] between these connectors as shown in the fig ...

Torque and Locking Agent
The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or silicone sealant etc. Letters used in the “Remarks” column mean: AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. G: Apply ...