Kawasaki Ninja Service Manual: Balancer Installation

Kawasaki Ninja Service Manual / Crankshaft/Transmission / Balancer / Balancer Installation

Position the crankshaft at #2, 3 positions TDC or at #1, 4 positions TDC.
Install the balancer assembly as follows.

Align the punch mark [A] on the weight and the projection [B] on the crankcase.

Engage the balancer gear and the crankshaft gear.

Insert the balancer shaft until it is bottomed.

Balancer Installation

Replace the balancer shaft oil seal with a new one.
Apply grease to the oil seal lips.
Install the oil seal so that its surface is flush with the end of hole.
Install: Balancer Shaft Clamp Lever [C]
Tighten: Torque - Balancer Shaft Clamp Bolt [D]: 9.8 N·m (1.0 kgf·m, 87 in·lb)
Turn the mark [A] on the balancer shaft to the engine forward [B].
Check that the lever [C] is in contact with the crankcase.
Tighten: Torque - Balancer Shaft Clamp Lever Bolt [D]: 25 N·m (2.5 kgf·m, 18 ft·lb)

Balancer Installation

Balancer Assemble

Apply molybdenum disulfide oil solution to the ribs of the balancer [A]. Apply molybdenum disulfide oil solution to the ribs of the balancer gear [A]. Check that the rubber dampers ...

Balancer Adjustment

Remove the left lower fairing (see Lower Fairing Removal in the Frame chapter). Start the engine and warm it up thoroughly. Adjust the balancer gear backlash with the engine idling. The a ...

Other materials:

Camshaft Installation
NOTE The exhaust camshaft has a 1001 EX mark [A] and the intake camshaft has a 3154 IN mark [B]. Be careful not to mix up these shafts. Install the camshaft sprockets as shown in the figure. #4 Cam Positions [A] Intake Camshaft Sprocket [B] Exhaust Camshaft Sprocket [C] The int ...

Transmission Shaft Disassembly
Remove the transmission shafts (see Transmission Shaft Removal). Remove the circlips, and then disassemble the transmission shafts. Special Tool - Outside Circlip Pliers: 57001-144 The 5th gear [A] on the output shaft has three steel balls assembled into it for the positive neutral fin ...

Valve Guide Installation
Apply engine oil to the valve guide outer surface before installation. Heat the area around the valve guide hole to about 120 150°C (248 302°F). NOTICE Do not heat the cylinder head with a torch. This will warp the cylinder head. Soak the cylinder head and heat the oil. Usin ...