Balancer Removal
- Split the crankcase (See Crankcase Splitting).
- Pull the balancer shaft [A] with the balancer gear out of the crankcase.
![](https://motoinstruction.ru/img/kawasaki/23/128679.jpg)
Balancer Installation
- Apply molybdenum disulfide oil solution to the inside of the balancer shaft bearing insert.
- Align [A] the timing mark on the balancer gear [B] with the timing mark on the balancer drive gear [C] of the crankshaft.
- Assemble the crankcase (See Crankcase Assembly).
![](https://motoinstruction.ru/img/kawasaki/23/128680.jpg)
Balancer Shaft Bearing Insert/Journal Clearance
- Measure the bearing insert/journal clearance using a plastigage.
Split the crankcase and wipe each bearing insert and journal surface clean of oil.
Cut strips of plastigage to bearing insert width, and place a strip on each journal parallel to the balancer shaft so that the plastigage will be compressed between the journal and the bearing insert.
Install the lower crankcase half, and tighten the case bolts to the specified torque (See Crankcase Assembly).
Note: Do not turn the balancer shaft during clearance measurement.
Remove the lower crankcase half and measure the plas-tigage width [A] to determine the bearing insert/journal [B] clearance.
![](https://motoinstruction.ru/img/kawasaki/23/128681.jpg)
Balancer Shaft Bearing Insert/Journal Clearance
Standard: 0.011-0.033 mm (0.0004-0.0013 in.)
Service Limit: 0.08 mm (0.0031 in.)
If the clearance is within the standard, no bearing insert replacement is required.
If the clearance is between 0.034 mm (0.00134 in.) and the service limit (0.08 mm (0.0031 in.)), replace the bearing inserts [A] with inserts painted blue [B] Check insert/journal clearance with a plastigage. The clearance may exceed the standard slightly, but it must not be less than the minimum in order to avoid bearing seizure.
If the clearance exceeds the service limit, measure the diameter of the balancer shaft journal.
![](https://motoinstruction.ru/img/kawasaki/23/128682.jpg)
Balancer Shaft Journal Diameter
Standard: 27.987-28.000 mm (1.1019-1.1024 in.)
Service Limit: 27.96 mm (1.1008 in.)
If either journal has worn past the service limit, replace the balancer shaft with a new one.
If the measured journal diameters are not less than the service limit, but do not coincide with the original diameter markings on the balancer shaft, write new marks on it.
Balancer Shaft Diameter Marks
None 27.987-27.993 mm (1.1019-1.1021 in.), 27.994-28.000 mm (1.1021-1.1024 in.)
Balancer Shaft Journal Diameter Marks, "O" mark or no mark.
![](https://motoinstruction.ru/img/kawasaki/23/128683.jpg)
- Put the lower crankcase half on the upper crankcase half without bearing inserts, and tighten the case bolts to the specified torque and sequence (See Crankcase Assembly).
- Measure the crankcase bearing bore diameter for the balancer shaft, and mark the upper crankcase half in accordance with the bore diameter.
![](https://motoinstruction.ru/img/kawasaki/23/128684.jpg)
Note: The mark already on the upper crankcase half should almost coincide with the measurement.
Crankcase Bearing Bore Diameter Marks
None 31.009-31.016 mm (1.2208-1.2211 in.), 31.000-31.008 mm (1.2205-1.2208 in.)
Crankcase Bearing Bore Diameter Marks, "О" mark or no mark.
- No.1 Journal [A]
- No.2 Journal [B]
- Select the proper bearing insert in accordance with the combination of the crankcase and the balancer shaft coding.
- Install the new inserts in the crankcase and check in-sert/journal clearance with a plastigage.
Balancer Shaft Bearing Insert Selection
Crankcase Main Bearing Bore Diameter Mark | Crankshaft Main Journal Diameter Mark | Bearing Insert* | |
Size Color | Part Number | ||
О | О | Brown | 92139-0119 |
О | None | Black | 92139-0118 |
None | О | ||
None | None | Blue | 92139-0117 |