Kawasaki Ninja Service Manual: Crankshaft Installation

Kawasaki Ninja Service Manual / Crankshaft/Transmission / Crankshaft and Connecting Rods / Crankshaft Installation

NOTE

If the crankshaft is replaced with a new one, refer to the Connecting Rod Big End Bearing/Crankshaft Main Bearing Insert Selection in the Specifications.

NOTICE

If the crankshaft, bearing inserts, or crankcase halves are replaced with new ones, select the bearing inserts and check clearance with a plastigage (press gauge) before assembling engine to be sure the correct bearing inserts are installed.

Apply molybdenum disulfide oil solution to the crankshaft main bearing inserts.
Install: Crankshaft Connecting Rod Big End Caps (see Connecting Rod Installation)
Apply molybdenum disulfide grease to the grooved side [A] of the thrust washers.
Insert the thrust washers into the groove of the #3 main journal [B].

Turn the oil groove side of the thrust washer to the crankshaft.

NOTE

The thrust washers are identical.
If the thrust washer installed properly, the blue-painted edges [C] are positioned as shown in the figure.

Crankshaft Installation

Front [D]

Connecting Rod Removal

Refer to the Piston Removal.

Crankshaft Removal

Split the crankcase (see Crankcase Splitting). Remove: Connecting Rod Big End Nuts [A] Connecting Rod Big End Caps [B] NOTE Mark and record the locations of the connecting rods and their ...

Connecting Rod Installation

NOTICE To minimize vibration, the connecting rods should have the same weight mark. Big End Cap [A] Connecting Rod [B] Weight Mark, Alphabet [C] Diameter Mark [D] (“” or No Mark) NOTICE ...

Other materials:

Thermostat Inspection
Remove the thermostat (see Thermostat Removal). Inspect the thermostat valve [A] at room temperature. If the valve is open, replace the thermostat with a new one. To check valve opening temperature, suspend the thermostat [A] in a container of water and raise the temperature of ...

Sidestand Switch Operation Inspection
Raise the rear wheel off the ground with the stand (see Rear Wheel Removal in the Wheels/Tires chapter). Inspect the sidestand switch [A] operation accordance to below table. Sidestand Switch Operation If the sidestand switch operation does not work, inspect or replace the foll ...

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 ...