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:

Moving Off
Check that the side stand is up. Pull in the clutch lever. Shift into 1st gear. Open the throttle a little, and start to let out the clutch lever very slowly. As the clutch starts to engage, open the throttle a littlemore, giving the engine just enough fuel to keep it from stallin ...

DFI System
1. ECU 2. Battery 3. Vehicle-down Sensor 4. Exhaust Butterfly Valve Actuator 5. Vacuum Chamber (Other than US, CA and CAL Models) 6. Air Intake Valve Actuator (Other than US, CA and CAL Models) 7. Air Intake Valve (Other than US, CA and CAL Models) 8. Air Flow 9. Air Intake Solenoid Valve ...

Battery Installation
Place the battery in the battery case. Connect the (+) cable to the (+) terminal, and then connect the (–) cable to the (–) terminal. NOTICE Installing the (–) cable to the (+) terminal of the battery or the (+) cable to the (–) terminal of the battery can seriously damaged ...