Kawasaki Ninja Service Manual: Upper Crankcase Assembly

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

When installing the breather plate, replace the gasket [A] with a new one.

Upper Crankcase Assembly

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)

Upper Crankcase Assembly

Install the fitting [A] until it is bottomed.

Special Tool - Bearing Driver Set: 57001-1129
Apply a non-permanent locking agent to the threads of the breather plug [B] and tighten it.

Torque - Breather Plug: 15 N·m (1.5 kgf·m, 11 ft·lb) View from Upside [C]
Install the plug [D] so that the plug surface [E] is flush with the end of the hole.

View from Left Side [F]

Upper Crankcase Assembly

Install the plate [A] as shown in the figure.
Apply a non-permanent locking agent to the plate bolts [B].
Tighten: Torque - Plate Bolts: 4.9 N·m (0.50 kgf·m, 43 in·lb) View from Right Side [C]

Upper Crankcase Assembly

Install: Oil Jet Nozzles (Black) (Part No.: 92062-0010) [A] Oil Jet Nozzles (White) (Part No.: 92062-0004) [B]
Tighten: Torque - Oil Jet Nozzles (M5): 2.9 N·m (0.30 kgf·m, 26 in·lb)

Upper Crankcase Assembly

Crankcase Assembly

NOTICE The upper and lower crankcase halves are machined at the factory in the assembled state, so the crankcase halves must be replaced as a set. With a high flash-point solvent, clean off the ...

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 ...

Other materials:

Charging Voltage Inspection
Check the battery condition (see Charging Condition Inspection). Warm up the engine to obtain actual alternator operating conditions. Remove the front seat (see Front Seat Removal in the Frame chapter). Check that the ignition switch is turned off, and connect the hand tester [A] to t ...

Spring Preload Adjustment
To adjust the spring preload, turn the spring preload adjuster [A]. The standard adjuster setting is the 6 turns in from the fully counterclockwise position. WARNINGIf both adjusters are not adjusted equally, handling may be impaired and a hazardous condition may result. B ...

Air Cleaner Housing Assembly
Install the ducts to the air cleaner housing. Fit the projections [A] of the duct into the slits [B] on the air cleaner housing. Tighten the screws [A]. Torque - Air Cleaner Housing Duct Screws: 1.1 N·m (0.11 kgf·m, 10 in·lb) Install: Air Cleaner Gasket [A] Duct [B] ...