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:

Sidestand Installation
Replace the sidestand nut [A] with a new one. Apply grease to the sliding areas [B]. Tighten the sidestand bolt [C] first, and then the sidestand nut. Torque - Sidestand Bolt: 44 N·m (4.5 kgf·m, 32 ft·lb) Sidestand Nut: 29 N·m (3.0 kgf·m, 21 ft·lb) Install the spring [D] as sh ...

What is a Limited Warranty?
The most important thing to know about your warranty is that it protects you from manufacturing defects in material or workmanship during the warranty period. You can find the warranty period in the Kawasaki Limited Warranty Certificate your Kawasaki dealer provided to you at the time of sale ...

Front Forks/Rear Shock Absorber Operation Inspection
Pump the forks down and up [A] 4 or 5 times, and inspect the smooth stroke. If the forks do not smoothly or noise is found, inspect the fork oil level or fork clamps (see Front Fork Oil Change in the Suspension chapter). Pump the rear seat down and up [A] 4 or 5 times, and inspec ...