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:

Rear Shock Absorber Scrapping
WARNINGPressurized nitrogen may explode when heated. The rear shock contains nitrogen gas. To avoid an explosion, do not incinerate the shock body without first releasing the nitrogen and removing the shraeder valve. Remove the rear shock absorber (see Rear Shock Ab ...

Windshield and Other Plastic Parts
After washing use a soft cloth to gently dry plastic parts. When dry, treat the windshield, headlight lens, and other nonpainted plastic parts with an approved plastic cleaner/polisher product. NOTICE Plastic parts may deteriorate and break if they come in contact with chemical substances ...

Exhaust Pipe Removal
Remove: Radiator (see Radiator and Radiator Fan Removal in the Cooling System chapter) Exhaust Pipe Clamp Bolt [A] (Loosen) Remove the exhaust pipe holder nuts [A], and pull out the exhaust pipe [B] forward from the premuffler chamber. ...