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:

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 Plate Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) Install the fitting [A] until it is bottomed ...

Rocker Arm/Tie-Rod Bearing, Sleeve Inspection
NOTICE Do not remove the bearings for inspection. Removal may damage them. Visually inspect the rocker arm, or tie-rod sleeves [A] and needle bearings [B]. The rollers in a needle bearing normally wear very little, and wear is difficult to measure. Instead of measuring, inspect the ...

Chain Slack Adjustment
Remove the cotter pin, and loosen the axle nut. Loosen the left and right chain adjuster locknuts. A. Axle Nut B. Cotter Pin C. Adjuster D. Locknut If the chain is too loose, turn out the left and right chain adjusters evenly. If the chain is too tight, turn in the left ...