Kawasaki Ninja Service Manual: Lower Crankcase Assembly

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

Install the ball bearing [A] and the oil level inspection window [B] until they are bottomed

Apply soap and water solution to the oil level inspection window before installation.

Install the new circlip [C].
Apply a non-permanent locking agent to the oil passage plug [D].
Tighten:

Torque - Oil Passage Plug (Taper): 20 N·m (2.0 kgf·m, 15 ft·lb) Oil Jet Nozzle (M10) [E]: 15 N·m (1.5 kgf·m, 11 ft·lb)

Lower Crankcase Assembly

View from Right Side [F]

Install the needle bearing [A] so that its surface is flush with the end of hole [B].
Replace the output shaft oil seal [C] and the shift shaft oil seal [D] with new ones, and install them.
Apply grease to the oil seal lips.
Install the oil jet nozzle [E] so that its surface is flush with the end of hole.

View from Left Side [F]

Lower Crankcase Assembly

Tighten: Torque -Oil Jet Nozzle (M8) [A]: 8.0 N·m (0.82 kgf·m, 71 in·lb) Oil Jet Nozzle (M6) [B]: 4.9 N·m (0.50 kgf·m, 43 in·lb)
Install: Dowel Pins [C] Dowel Pin (Pipe) [D]

Lower Crankcase Assembly

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 ...

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 ...

Other materials:

Clutch Installation
Apply engine oil to the needle bearing [A] and the sleeve [B]. Install: Needle Bearing Sleeve Install the clutch housing [A]. Fit the holes [B] and projections [C]. Engage the clutch housing gear and the crankshaft primary gear. Install the spacer [A] and the clutch ...

Torque and Locking Agent
The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or silicone sealant etc. Letters used in the “Remarks” column mean: AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. G: Apply ...

Battery Installation
Place the battery in the battery case. Connect the (+) cable to the (+) terminal, and then connect the (–) cable to the (–) terminal. NOTICE Installing the (–) cable to the (+) terminal of the battery or the (+) cable to the (–) terminal of the battery can seriously damaged ...