Kawasaki Ninja Service Manual: Crankshaft Installation

Kawasaki Ninja Service Manual / Crankshaft/Transmission / Crankshaft and Connecting Rods / Crankshaft Installation

NOTE

If the crankshaft is replaced with a new one, refer to the Connecting Rod Big End Bearing/Crankshaft Main Bearing Insert Selection in the Specifications.

NOTICE

If the crankshaft, bearing inserts, or crankcase halves are replaced with new ones, select the bearing inserts and check clearance with a plastigage (press gauge) before assembling engine to be sure the correct bearing inserts are installed.

Apply molybdenum disulfide oil solution to the crankshaft main bearing inserts.
Install: Crankshaft Connecting Rod Big End Caps (see Connecting Rod Installation)
Apply molybdenum disulfide grease to the grooved side [A] of the thrust washers.
Insert the thrust washers into the groove of the #3 main journal [B].

Turn the oil groove side of the thrust washer to the crankshaft.

NOTE

The thrust washers are identical.
If the thrust washer installed properly, the blue-painted edges [C] are positioned as shown in the figure.

Crankshaft Installation

Front [D]

Connecting Rod Removal

Refer to the Piston Removal.

Crankshaft Removal

Split the crankcase (see Crankcase Splitting). Remove: Connecting Rod Big End Nuts [A] Connecting Rod Big End Caps [B] NOTE Mark and record the locations of the connecting rods and their ...

Connecting Rod Installation

NOTICE To minimize vibration, the connecting rods should have the same weight mark. Big End Cap [A] Connecting Rod [B] Weight Mark, Alphabet [C] Diameter Mark [D] (“” or No Mark) NOTICE ...

Other materials:

Vehicle-down Sensor Installation
Be sure to install the rubber dampers [A] and collars [B] on the bracket. The UP mark [A] of the sensor should face upward. WARNINGIncorrect installation of the vehicle-down sensor could cause sudden loss of engine power. The rider could lose balance during certain ...

Flap and Rear Fender Rear Installation
Installation is the reverse of removal. Note the following. Fit the tab [A] to the slot [B]. Run the seat lock cable [C] between the tool kit case and the turn signal light as shown in the figure. When installing the dampers [A] on the lower pipe [B], install it as shown in the figure. ...

Shift Drum Assembly
Press and insert the ball bearing [A] on the shift drum [B] until it is bottomed. Install: Ball Bearing [C] Dowel Pin [D] and Shift Drum Cam [E] Align the pin with the groove in the shift drum cam. Apply a non-permanent locking agent to the shift drum cam holder bolt [F]. Tight ...