Kawasaki Ninja Service Manual: Crankcase Splitting

Kawasaki Ninja Service Manual / Crankshaft/Transmission / Crankcase / 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: Cylinder Head (see Cylinder Head Removal in the Engine Top End chapter) Starter Motor (see Starter Motor Removal in the Electrical System chapter) Oil Pump (see Oil Pump Removal in the Engine Lubrication System chapter) Alternator Rotor (see Alternator Rotor Removal in the Electrical System chapter) Transmission Assy (see Transmission Assy Removal) Oil Cooler (see Oil Cooler Removal in the Engine Lubrication System chapter) Oil Pan (see Oil Pan Removal in the Engine Lubrication System chapter) Oil Screen
Remove the upper crankcase bolts, following the specified sequence.

1. Loosen the M7 bolt [A].

2. Loosen the M8 bolts [B].

Crankcase Splitting

Remove the lower crankcase bolts, following the specified sequence.

1. Loosen the M6 bolts [A].

2. Loosen the M7 bolts [B].

3. Loosen the M9 bolts [C].

Tap lightly around the crankcase mating surface with a plastic mallet, and split the crankcase.

Take care not to damage the crankcase.

Crankcase Splitting

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 ...

Other materials:

DFI Servicing Precautions
There are a number of important precautions that should be followed servicing the DFI system. This DFI system is designed to be used with a 12 V sealed battery as its power source. Do not use any other battery except for a 12 V sealed battery as a power source. Do not reverse the battery ...

Gear Position Switch Installation
Securely place the springs [A] and pins [B] into the holes [C] of the shift drum. Apply grease to the new O-ring [D]. Install the gear position switch [E]. Apply a non-permanent locking agent to the threads of the gear position switch screws [F]. Tighten: Torque - Gear Position Swit ...

Wiring Diagram (US, CA and CAL with KIBS Models)
ZX1000KC ZX1000KD ...