Crankcase Splitting
- Remove the engine (See Engine Removal in the Engine Removal/Installation chapter)
- Set the engine on a clean surface and hold the engine steady while parts are being removed.
Remove:
- Cylinder Head (See Cylinder Head Removal in the Engine Top End chapter)
- Cylinder (see Cylinder Removal in the Engine Top End chapter)
- Pistons (see Piston Removal in the Engine Top End chapter)
- Starter Motor (See Starter Motor Removal in the Electrical System chapter)
- Crankshaft Sensor (See Crankshaft Sensor Removal in the Electrical System chapter)
- Timing Rotor (See Timing Rotor Removal in the Electrical System chapter)
- Alternator Rotor (See Alternator Rotor Removal in the Electrical System chapter)
- Clutch (See Clutch Removal in the Clutch chapter)
- Oil Pump (See Oil Pump Removal in the Engine Lubrication System chapter)
- Water Pump (See Water Pump Removal in the Cooling System chapter)
- Transmission Assy (See Transmission Assy Removal)
- Remove the upper crankcase bolts [A] and the washers.
![](https://motoinstruction.ru/img/kawasaki/23/128630.jpg)
- Remove the oil pan, oil screen and oil pipes (See Oil Pan Removal in the Engine Lubrication System chapter).
- Remove the lower crankcase bolts, following the specified sequence.
Firstly, loosen the M6 bolts [A].
Secondly, loosen the M8 bolts [B].
Lastly, loosen the M9 bolts [C].
- Tap lightly around the crankcase mating surface with a plastic mallet, and split the crankcase. Take care not to damage the crankcase.
![](https://motoinstruction.ru/img/kawasaki/23/128631.jpg)
If the oil pipe is to be removed, follow the next procedure. OUnscrew the bolts [A] and remove the oil pipe [B].
![](https://motoinstruction.ru/img/kawasaki/23/128632.jpg)
Prepare a ∅5 mm rod [A], and insert it to the hole of the upper crankcase half.
Remove the oil pipe [B], tapping [C] the rod as shown.
![](https://motoinstruction.ru/img/kawasaki/23/128633.jpg)
If the breather plate [A] is to be removed, follow the next procedure.
Remove the oil pipe (see above).
Cut the gasket around the plate [B].
Remove:
- Breather Plate Bolts [C]
- Breather Plate with Pipe [D]
![](https://motoinstruction.ru/img/kawasaki/23/128634.jpg)
Crankcase Assembly
Caution: 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 mating surfaces of the crankcases halves and wipe dry.
- Using compressed air, blow out the oil passages in the crankcase halves.
If the oil plate [A] on the upper crankcase half was removed, install it as shown.
Apply a non-permanent locking agent to the oil plate bolts and tighten them.
Torque - Oil Plate Bolts [B]: 9.8 Nm (1.0 Nm 87 in·lb)
![](https://motoinstruction.ru/img/kawasaki/23/128635.jpg)
- When the new needle bearing [A] for the shift drum is installed in the lower crankcase half [B], press and insert [C] the new needle bearing until it is bottomed.
Special Tool - Bearing Driver Set: 57001-1129
- When the new needle bearing [D] for the shift shaft is installed in the lower crankcase half, press and insert [E] the new needle bearing so that the bearing surface is flush with the end of hole.
Special Tool - Bearing Driver Set: 57001-1129
![](https://motoinstruction.ru/img/kawasaki/23/128636.jpg)
- When the new oil plug [A] and new race [B] for drive shaft is installed in the upper crankcase half [C], install them using the following steps.
Apply grease to the new O-rings [D].
Apply silicone sealant to the portions [E] on the upper crankcase half, and insert [F] the new oil plug until it is bottomed.
Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004
Press and insert the new race until it is bottomed.
Special Tool - Bearing Driver Set: 57001-1129
![](https://motoinstruction.ru/img/kawasaki/23/128637.jpg)
Note: lnstall the new race so that the stepped side [G] faces inside of the crankcase. Install the race holder [H] direction as shown. Apply a non-permanent locking agent to the threads of the race holder screw [I] and tighten it.
Torque - Race Holder Screw: 4.9 №m (0.50 kgf·m 43 in·lb)
- Apply silicone sealant to the breather plate mating surface [A] 1 mm (0.04 in.) or more thick, and then install the breather plate.
Sealant - Three Bond: TB1207B
![](https://motoinstruction.ru/img/kawasaki/23/128638.jpg)
Note: Make the application finish within 7 minutes when the liquid gasket to the mating surface of the breather plate is applied. Moreover fit the plate and tighten the bolts just after application of the liquid gasket.
- Apply a non-permanent locking agent to the threads and tighten the bolts [A].
Torque - Breather Plate Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
![](https://motoinstruction.ru/img/kawasaki/23/128639.jpg)
- Install the breather pipe [A].
Align the white mark [B] on the pipe with the white mark [C] on the breather fitting.
Install the clamps [D] so that the pinch heads [E] face the white marks.
![](https://motoinstruction.ru/img/kawasaki/23/128640.jpg)
- Install the oil pipe [A] so that its flange [B] touches to the surface [C] of the upper crankcase half.
- Apply grease to the new O-ring [D] on the oil pipe.
![](https://motoinstruction.ru/img/kawasaki/23/128641.jpg)
- Replace the O-rings [A] with new ones.
- Apply grease to the new O-rings.
- Apply a non-permanent locking agent to the threads of the oil pipe bolts and tighten them.
Torque - Oil Pipe Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
![](https://motoinstruction.ru/img/kawasaki/23/128642.jpg)
- Install the crankshaft and the balancer shaft on the upper crankcase half.
Align [A] the timing mark on the balancer gear [B] with the timing mark on the balancer drive gear [C] of the crankshaft.
![](https://motoinstruction.ru/img/kawasaki/23/128643.jpg)
- Be sure to hang the camshaft chain [A] on the crankshaft.
![](https://motoinstruction.ru/img/kawasaki/23/128644.jpg)
- Be sure that the dowel pins [A] are in position.
![](https://motoinstruction.ru/img/kawasaki/23/128645.jpg)
- Set the bearing groove [A] on the positioning ring [B] as shown.
![](https://motoinstruction.ru/img/kawasaki/23/128646.jpg)
- Apply liquid gasket [A] to the mating surface of the lower crankcase half.
Sealant - Kawasaki Bond: 92104-1064
Note: Especially, apply a liquid gasket carefully so that it shall be filled up on the grooves.
Caution: Do not apply liquid gasket around the crankshaft main bearing inserts, and oil passage holes. Do not apply liquid gasket to the oil passage [B].
![](https://motoinstruction.ru/img/kawasaki/23/128647.jpg)
- Fit the lower crankcase half to the upper crankcase half. Olnsert [A] the breather pipe [B] on the upper crankcase half through the hole [C] on the lower crankcase half.
Note: Make the application finish within 20 minutes when the liquid gasket to the mating surface of the lower crankcase half is applied. Moreover fit the case and tighten the case bolts just after finishing the application of the liquid gasket.
![](https://motoinstruction.ru/img/kawasaki/23/128648.jpg)
- The M9 bolts [1-6] (see the next figure) have copper plated washers, replace them with new ones.
- Apply molybdenum disulfide oil solution to both sides [A] of the M9 bolts washers and the threads [B] of the M9 bolts.
![](https://motoinstruction.ru/img/kawasaki/23/128649.jpg)
- Apply molybdenum disulfide oil solution to flange [A] and the threads [B] of the M8 bolts which is tightening order is [7-10] only (see the next figure).
![](https://motoinstruction.ru/img/kawasaki/23/128650.jpg)
- Tighten the lower crankcase bolts using the following steps.
Following the sequence numbers on the lower crankcase half, tighten the M9 bolts [1, 2] L= 113 mm (4.45 in.) with washers.
Torque - Crankcase Bolts (M9): 44 Nm (4.5 kgf·m, 32 ft·lb)
Tighten the M9 bolts [3, 4] L= 83 mm (3.27 in.) with washers.
Torque - Crankcase Bolts (M9): 44 Nm (4.5 kgf·m, 32 ft·lb)
Tighten the M9 bolts [5, 6] L= 113 mm (4.45 in.) with washers.
Torque - Crankcase Bolts (M9): 44 №m (4.5 kgf·m, 32 ft·lb)
Tighten the M8 bolts [7-10].
Torque - Crankcase Bolts (M8): 35 Nm (3.6 kgf·m, 26 ft·lb)
Tighten the M8 bolts [A] (do not apply molybdenum oil solution).
Torque - Crankcase Bolts (M8): 27.5 Nm (2.8 kgf·m, 20 ft·lb)
Tighten the M6 bolts [B].
Torque - Crankcase Bolts (M6): 19.6 Nm (2.0 kgf·m, 14 ft·lb)
![](https://motoinstruction.ru/img/kawasaki/23/128651.jpg)
- The upper crankcase bolts have copper plated washers, replace them with new ones.
- Tighten the upper crankcase bolts with washers.
Torque - Upper Crankcase Bolts [A]: 27.5 Nm (2.8 kgf·m 20 ft·lb)
![](https://motoinstruction.ru/img/kawasaki/23/128652.jpg)
- After tightening all crankcase bolts, check the following items.
Wipe up the liquid gasket that seeps out around the crankcase mating surface.
Crankshaft and balancer shaft turn freely.