Kawasaki Ninja Service Manual: Crankcase Assembly

Kawasaki Ninja Service Manual / Crankshaft/Transmission / Crankcase / 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 mating surfaces of the crankcase halves and wipe dry

WARNING

Gasoline and low flash-point solvents can be flammable and/or explosive and cause severe burns. Clean the crankcase in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area; this includes any appliance with a pilot light. Do not use gasoline or a low flash-point solvent to clean the crankcase.

Using compressed air, blow out the oil passages in the crankcase halves.
Install the balancer (see Balancer Installation).

Crankcase Splitting

Remove the engine (see Engine Removal in the Engine Removal/Installation chapter). Set the engine on a clean surface and hold the engine steady while parts are being removed. Remove: Cyli ...

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 ...

Other materials:

Terminal Numbers of ECU Connectors
1. Subthrottle Valve Actuator: Y/BK 2. Subthrottle Valve Actuator: BK/O 3. Unused 4. Front Wheel Rotation Sensor Signal: G/Y 5. Unused 6. Starter Lockout Switch: R/G 7. Gear Position Switch: G/R 8. Crankshaft Sensor (–): BK 9. Power Supply to Sensors: BL 10. Unused 11. Intake Air Pre ...

Coolant Flow Chart
1. Radiator 2. Radiator Fan 3. Water Pump 4. Oil Cooler 5. Oil Cooler Intake Hose 6. Oil Cooler Outlet Hose 7. Cylinder Jacket 8. Cylinder Head Jacket 9. Thermostat Housing 10. Air Bleeder Hose 11. Radiator Cap 12. Radiator Overflow Hose 13. Reserve Tank 14. Reserve Tank Overflow Ho ...

Caliper Installation
Install the caliper and brake hose lower end. For the front caliper, be sure to install the collars [A]. Replace the washers on each side of hose fitting with new ones. Touch the brake hoses [A] to the stopper [B] of the caliper. Front Calipers [C] Rear Caliper [D] Tighten: To ...