Kawasaki Ninja Service Manual: 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:

Intake Air Temperature Sensor Removal
NOTICE Never drop the intake air temperature sensor especially on a hard surface. Such a shock to the sensor can damage it. Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter). Disconnect the connector [A] from the intake air temperature sensor. Remove the da ...

Drive Chain Slack Adjustment
Remove the cotter pin [A], and loosen the rear axle nut [B]. Loosen the both chain adjuster locknuts [C]. If the chain is too loose, turn out the left and right chain adjusters [D] evenly. If the chain is too tight, turn in the left and right chain adjusters evenly, and kick the wheel f ...

Cylinder (Upper Crankcase) Wear Inspection
Split the crankcase (see Crankcase Splitting). Remove the pistons (see Piston Removal). Assemble the cylinder (upper crankcase) [A], the cylinder head [B] and the cylinder head gasket [C]. Tighten the cylinder head bolts (see Cylinder Head Installation in the Engine Top End chapter). ...