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:

Fuel Pump Installation
Remove dirt or dust from the fuel pump [A] by lightly applying compressed air. Replace the fuel pump gasket with a new one. Check that the fuel pump terminal [A] and band [B] are in place. Apply a non-permanent locking agent to the threads of the fuel pump bolts. Tighten the ...

Air Intake Solenoid Valve (Service Code 2d, Equipped Models)
Air Intake Solenoid Valve Removal/Installation Refer to the Air Intake Solenoid Valve Removal/Installation in the Fuel System (DFI) chapter. Air Intake Solenoid Valve Inspection Refer to the Air Intake Solenoid Valve Unit Test in the Electrical System chapter. If the air intake ...

Engine Sprocket Installation
Replace the sprocket washer and axle cotter pin. Install the engine sprocket onto the output shaft. Apply molybdenum disulfide oil solution to the threads and seating surface of the engine sprocket nut. Tighten: Torque - Engine Sprocket Nut: 145 N·m (14.8 kgf·m, 107 ft·lb) NOTE ...