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:

Lap Counter/Coolant/Intake Air Temperature Meter
This meter shows the coolant temperature, the intake air temperature or the lap number. The lap number is displayed in the stop watch mode, refer to the “Stop Watch” item in this section. A. Lap Counter/Coolant / Intake Air Temperature Meter The coolant temperature meter and inta ...

For Primary Fuel Injectors
Remove the air cleaner housing (see Air Cleaner Housing Removal). Disconnect the injector connector and connect the harness adapter [A] between these connectors as shown in the figure. Main Harness [B] Primary Fuel Injector #1 [C] Special Tool - Measuring Adapter: 57001-1700 ...

Passenger’s Seat Installation
Insert the tab on the rear of the passenger’s seat into the slot in the frame. Insert the projections at the front of the passenger’s seat into the holes on the frame. Push down the front part of the passenger’s seat until the lock clicks. A. Passenger’s Seat B. Proj ...