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:

Rear Brake Pad Installation
Check that the pad spring is in place on the caliper. Push the caliper piston in as far as it will go. Install the piston side pad [A] first, and then another pad. Fit the brake pad end into the recess [B] of the caliper holder. Install the pad pin and the plug. Tighten: Torque - ...

Nozzle Assy Installation
Replace the dust seals [A] with new ones. Apply engine oil to the new dust seals, and install them. Install the nozzle assy securely. Push the four mounting positions of the injectors. Set the joint pipe parallel to the air cleaner housing [B]. NOTICE When installing the nozzle assy, ap ...

Fuel Hose Replacement
Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter). WARNINGFuel is flammable and explosive under certain conditions and can cause severe burns. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. When the fue ...