Kawasaki Ninja Service Manual: Lower Crankcase Assembly

Kawasaki Ninja Service Manual / Crankshaft/Transmission / Crankcase / Crankcase Assembly / 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 the new circlip [C].
Apply a non-permanent locking agent to the oil passage plug [D].
Tighten:

Torque - Oil Passage Plug (Taper): 20 N·m (2.0 kgf·m, 15 ft·lb) Oil Jet Nozzle (M10) [E]: 15 N·m (1.5 kgf·m, 11 ft·lb)

Lower Crankcase Assembly

View from Right Side [F]

Install the needle bearing [A] so that its surface is flush with the end of hole [B].
Replace the output shaft oil seal [C] and the shift shaft oil seal [D] with new ones, and install them.
Apply grease to the oil seal lips.
Install the oil jet nozzle [E] so that its surface is flush with the end of hole.

View from Left Side [F]

Lower Crankcase Assembly

Tighten: Torque -Oil Jet Nozzle (M8) [A]: 8.0 N·m (0.82 kgf·m, 71 in·lb) Oil Jet Nozzle (M6) [B]: 4.9 N·m (0.50 kgf·m, 43 in·lb)
Install: Dowel Pins [C] Dowel Pin (Pipe) [D]

Lower Crankcase Assembly

Upper Crankcase Assembly

When installing the breather plate, replace the gasket [A] with a new one. Apply a non-permanent locking agent to the threads of the bolts [A] and tighten them. Torque - Breather ...

Crankcase Halves Assembly

Install: Crankshaft (see Crankshaft Installation) Connecting Rods (see Connecting Rod Installation) Using a cleaning fluid, clean off any oil or dirt on the mating surface of the crankcase ...

Other materials:

ECU Removal
NOTICE Never drop the ECU especially on a hard surface. Such a shock to the ECU can damage it. Remove the upper air cleaner housing (see Air Cleaner Element Replacement in the Periodic Maintenance chapter). Lift up the ECU [A] with rubber protector [B] to disconnect the connectors [C]. ...

Upper Fairing Assembly Removal
Remove: Lower Fairings (see Lower Fairing Removal) Center Inner Fairing (see Center Inner Fairing Removal) Upper Inner Fairings (see Upper Inner Fairing Removal) Windshield (see Windshield Removal) Disconnect the front turn signal light lead connector [A] (both sides). Remove the bo ...

Inquiries to Rider
Each rider reacts to problems in different ways, so it is important to confirm what kind of condition the rider is dissatisfied with. Try to find out exactly what problem occurs under exactly what conditions by asking the rider; knowing this information may help you reproduce the prob ...