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:

Cylinder Compression Measurement
NOTE Use the battery which is fully charged. Warm up the engine thoroughly. Stop the engine. Remove the spark plugs (see Spark Plug Replacement in the Periodic Maintenance chapter). Attach the compression gauge [A] and adapter [B] firmly into the spark plug hole. Using the startermo ...

Brake Pedal Position Adjustment
NOTE Usually it is not necessary to adjust the pedal position, but always adjust it when push rod locknut has been loosened. Loosen the locknut [A] and turn the push rod with the hex head [B] to achieve the correct pedal position. If the length [C] shown is 69 ±1 mm (2.7 ±0.04 in.), th ...

Exploded View
5. Other than US, CA, and CAL Models 6. The big diameter side of the dampers faces upward. G: Apply grease. L: Apply a non-permanent locking agent. R: Replacement Parts S: Follow the specified tightening sequence. SS: Apply silicone sealant. 11. Immobilizer Ampli ...