Kawasaki Ninja Service Manual: 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 halves.
• Apply liquid gasket to the mating surface of the lower crankcase half as shown in the figure.

Sealant - Liquid Gasket, TB1216B [A]: 92104-1064 Liquid Gasket, TB1207B [B]: 92104-2068

NOTE

• Especially, apply a sealant so that it shall be filled up on the groove [C].
• Do not apply liquid gasket to the inside of the grooves [D].

NOTICE

Do not apply liquid gasket around the crankshaft main bearing inserts and oil passage.

• Fit the lower crankcase half to the upper crankcase half.

NOTE

• Make the application finish within 20 minutes when the liquid gasket (TB1216B) to the mating surface of the lower crankcase half is applied.
• Make the application finish within 7 minutes when the liquid gasket (TB1207B) to the mating surface of the lower crankcase half is applied.
• Moreover fit the case and tighten the bolts just after application of the liquid gasket.

Install the drive shaft bearing [A].

Special Tool - Bearing Driver Set: 57001-1129

Face the oil seal side of the bearing to the bottom.

• The M8 bolt [A] has a copper plated washer [B], replace them with new ones.
• Apply molybdenum disulfide oil solution to both sides [C] of the washers and threads [D].

• Tighten the lower crankcase bolts with the following procedures.

  Install the M9 bolts and washers.

L = 113 mm (4.45 in.) [A] L = 100 mm (3.94 in.) [B]

Tighten M9 bolts by following the sequence numbers [1
10].

Torque - Lower Crankcase Bolts (M9): 45 N·m (4.6 kgf·m, 33 ft·lb)

Install the M7 bolts.

L = 50 mm (2.0 in.) [A] L = 45 mm (1.8 in.) [B] Tighten:

Torque - Lower Crankcase Bolts (M7): 20 N·m (2.0 kgf·m, 15 ft·lb)

Replace the M6 bolt washers with new ones.

Install the M6 bolts.

L = 60 mm (2.4 in.) [A] (With Washer) L = 45 mm (1.8 in.) [B] L = 40 mm (1.6 in.) [C]

Install the clamp [D] and washer [E] as shown in the figure.

Tighten:

Torque - Lower Crankcase Bolts (M6): 12 N·m (1.2 kgf·m, 106 in·lb)

• Tighten the upper crankcase bolts with the following procedures.

Replace the M8 bolt washers with new ones.

Install the M8 bolts [A] and washers.

Install the M7 bolt [B].

Tighten:

Torque - Upper Crankcase Bolts (M8): 27 N·m (2.8 kgf·m, 20 ft·lb) Upper Crankcase Bolt (M7): 20 N·m (2.0 kgf·m, 15 ft·lb)

• After tightening all crankcase bolts, check the following items.

Wipe up the liquid gasket that seeps out around the crankcase mating surface.

Crankshaft turns freely.

• Press the drive shaft bearing until it is bottomed.
• Install:

Drive Shaft Bearing Holder [A] Output Shaft Bearing Holder [B]

Turn the flat side [C] of the holders to inside.

• Apply a non-permanent locking agent to the bearing holder bolts [D].
• Tighten: Torque - Bearing Holder Bolts: 15 N·m (1.5 kgf·m, 11 ft·lb)
• Install the removed parts (see appropriate chapters).