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:

Drive Chain Wear Inspection
Remove the chain cover (see Drive Chain Removal/Installation in the Final Drive chapter). Rotate the rear wheel to inspect the drive chain for damaged rollers, and loose pins and links If there is any irregularity, replace the drive chain. Lubricate the drive chain if it appears dry. ...

Fuel Tank Removal
WARNINGGasoline is extremely flammable and can be explosive under certain conditions, creating the potential for serious burns. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. T ...

Torque Limiter Installation
Apply molybdenum disulfide grease to the torque limiter shaft [A]. Install the torque limiter [B], the collar [C] and the shaft. Turn the large-hole end of the shaft to inside as shown in the figure. Replace the washer [D] with a new one. Apply a non-permanent locking agent to the t ...