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:

Exhaust Pipe Installation
Replace the exhaust pipe gaskets [A] and premuffler chamber gasket [B] with new ones. Install the premuffler chamber gasket to the premuffler chamber [C] until it is bottomed so that the chamfer side faces exhaust pipe [D]. Install the exhaust pipe clamp [E] as shown in the figure. I ...

Valve Guide Removal
Remove: Valve (see Valve Removal) Oil Seal Spring Seat Heat the area around the valve guide to 120 150°C (248 302°F), and hammer lightly on the valve guide arbor [A] to remove the guide from the top of the head. NOTICE Do not heat the cylinder head with a torch. This ...

Air Switching Valve Removal
NOTICE Never drop the air switching valve especially on a hard surface. Such a shock to the air switching valve can damaged it. Remove the air cleaner housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter). Disconnect the connector [A]. Disconnect the hoses [B] from ...