Kawasaki Ninja Service Manual: Crankcase Assembly

Kawasaki Ninja Service Manual / Crankshaft/Transmission / Crankcase / Crankcase Assembly

NOTICE

The upper and lower crankcase halves are machined at the factory in the assembled state, so the crankcase halves must be replaced as a set.

With a high flash-point solvent, clean off the mating surfaces of the crankcase halves and wipe dry

WARNING

Gasoline and low flash-point solvents can be flammable and/or explosive and cause severe burns. Clean the crankcase in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area; this includes any appliance with a pilot light. Do not use gasoline or a low flash-point solvent to clean the crankcase.

Using compressed air, blow out the oil passages in the crankcase halves.
Install the balancer (see Balancer Installation).

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 ...

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 ...

Other materials:

Water Temperature Sensor Resistance Inspection
Refer to the Water Temperature Sensor Inspection in the Electrical System chapter. If the reading is within the standard, but the problem still exists, replace the ECU (see ECU Removal/Installation in the Fuel System (DFI) chapter). Water Temperature Sensor Circuit 1. ECU 2. Water T ...

Oxygen Sensor Heater Power Source Voltage Inspection
NOTE Be sure the battery is fully charged. Turn the ignition switch to OFF. Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter). Disconnect the oxygen sensor lead connector and connect the measuring adapter [A] between these connectors as shown in the fig ...

Coolant Change
WARNINGCoolant can be extremely hot and cause severe burns, is toxic and very slippery. Do not remove the radiator cap or attempt to change the coolant when the engine is hot; allow it cool completely. Immediately wipe any spilled coolant from tires, frame, engine or othe ...