Kawasaki Ninja Service Manual: Crankcase

Kawasaki Ninja Service Manual / Crankshaft/Transmission / Crankcase

Special Tools and Sealants
Outside Circlip Pliers: 57001-144 Piston Pin Puller Assembly: 57001-910 Piston Ring Compressor Grip: 57001-1095 Piston Ring Compressor Belt, 67 79: 57001-1097 Bearing Driver Set: 57001 ...

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: Cyli ...

Other materials:

External Shift Mechanism Inspection
Examine the shift shaft [A] for any damage. If the shaft is bent, straighten or replace it. If the serration [B] are damaged, replace the shaft. If the spring [C] is damaged in any way, replace it. If the shift mechanism arm [D] is damaged in any way, replace the shaft. Check the s ...

Clutch Plate, Wear, Damage Inspection
Visually inspect the friction and steel plates for signs of seizure, overheating (discoloration), or uneven wear. Measure the thickness of each friction plate [A] at several points. If any plates show signs of damage, or if they have worn past the service limit, replace them with new on ...

Spring Tension Inspection
Since a spring becomes shorter as it weakens, check its free length [A] to determine its condition. If the spring of either fork leg is shorter than the service limit, it must be replaced. If the length of a replacement spring and that of the remaining spring vary greatly, the remaining s ...