Kawasaki Ninja Service Manual: Crankcase Splitting

• Remove the engine (see Engine Removal in the Engine Removal/Installation chapter).
• Set the engine on a clean surface and hold the engine steady while parts are being removed.
• Remove: Cylinder Head (see Cylinder Head Removal in the Engine Top End chapter) Starter Motor (see Starter Motor Removal in the Electrical System chapter) Oil Pump (see Oil Pump Removal in the Engine Lubrication System chapter) Alternator Rotor (see Alternator Rotor Removal in the Electrical System chapter) Transmission Assy (see Transmission Assy Removal) Oil Cooler (see Oil Cooler Removal in the Engine Lubrication System chapter) Oil Pan (see Oil Pan Removal in the Engine Lubrication System chapter) Oil Screen
• Remove the upper crankcase bolts, following the specified sequence.

  1. Loosen the M7 bolt [A].

  2. Loosen the M8 bolts [B].

• Remove the lower crankcase bolts, following the specified sequence.

1. Loosen the M6 bolts [A].

2. Loosen the M7 bolts [B].

3. Loosen the M9 bolts [C].

• Tap lightly around the crankcase mating surface with a plastic mallet, and split the crankcase.

Take care not to damage the crankcase.