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:

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

Stopping the engine
Close the throttle completely. Shift the transmission into neutral Turn the ignition key to “OFF”. Support the motorcycle on a firm, level surface with the side stand. Lock the steering. NOTE The motorcycle is equipped with a vehicle-down sensor, which causes the engine to sto ...

Radiator Inspection
Remove the radiator (see Radiator and Radiator Fan Removal). Check the radiator core. If there are obstructions to air flow, remove them. If the corrugated fins [A] are deformed, carefully straighten them. If the air passages of the radiator core are blocked more than 20% by unremovable ...