Kawasaki Ninja Service Manual: Crankcase Splitting

Kawasaki Ninja Service Manual / Crankshaft/Transmission / Crankcase / 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: Cylinder Head (see Cylinder Head Removal in the Engine Top End chapter) Starter Motor (see Starter Motor Removal in the Electrical System chapter) Oil Pump (see Oil Pump Removal in the Engine Lubrication System chapter) Alternator Rotor (see Alternator Rotor Removal in the Electrical System chapter) Transmission Assy (see Transmission Assy Removal) Oil Cooler (see Oil Cooler Removal in the Engine Lubrication System chapter) Oil Pan (see Oil Pan Removal in the Engine Lubrication System chapter) Oil Screen
Remove the upper crankcase bolts, following the specified sequence.

1. Loosen the M7 bolt [A].

2. Loosen the M8 bolts [B].

Crankcase Splitting

Remove the lower crankcase bolts, following the specified sequence.

1. Loosen the M6 bolts [A].

2. Loosen the M7 bolts [B].

3. Loosen the M9 bolts [C].

Tap lightly around the crankcase mating surface with a plastic mallet, and split the crankcase.

Take care not to damage the crankcase.

Crankcase Splitting

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 ...

Other materials:

Exhaust Butterfly Valve Cable Installation
Confirm whether pulley [A] is an angle shown in the figure. 41.7° ±7° [B] This position is original position of the pulley. NOTE Correct the position electrically after confirming the use is discontinued and there is no damage when differing from the angle of shown in the figure. ...

Subthrottle Valve Actuator Input Voltage Inspection
NOTE Be sure the battery is fully charged. Turn the ignition switch to OFF. Disconnect the subthrottle valve actuator connector and connect the measuring adapter [A] between these connectors as shown in the figure. Main Harness [B] Subthrottle Valve Actuator [C] Special Tool ...

Wiring Diagram (US, CA and CAL with KIBS Models)
ZX1000KC ZX1000KD ...