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.
Apply silicone sealant to the breather plate mating surface [A] 1 to 1.5 mm thick, wait until sealant dries, and then install the breather plate [B].
Sealant - Kawasaki Bond (Silicone Sealant): 92104-1063
Apply a non-permanent locking agent to the threads and tighten the bolts [C].
Torque - Breather Plate Bolts: 9.8 N·m (1.0 kg·m, 87 in·lb)
Install:
- Crankshaft and Connecting Rods
- Camshaft Chain [A]
- Transmission Shaft and Gears
- Dowel Pins [B]
- Shift Drum
- Shift Forks and Shift Rods
Before fitting the lower case on the upper case, check the following.
Be sure to hang the camshaft chain on the crankshaft.
Check to see that the shift drum and transmission gears are in the neutral position.
Apply liquid gasket [A] to the mating surface of the lower crankcase half.
Sealant- Kawasaki Bond (Silicone Sealant): 92104-1063
Caution! Do not apply liquid gasket around the crankshaft main bearing inserts, and oil passage holes.
Tighten the lower crankcase bolts.
Following the sequence numbers on the lower crankcase half, tighten the 8 mm bolts [1-10].
Torque - Crankcase 8 mm Bolts: 30 N·m (3.0 kg·m, 22 ft·lb)
Install the brackets [A] and tighten the 6 mm bolts [B].
Torque - Crankcase (L38 mm) 6 mm Bolts: 18 N·m (1.8 kg·m, 13.0 ft·lb)
Tighten the 6 mm bolts [C].
Torque - Crankcase 6 mm Bolts: 12 N·m (1.2 kg·m, 104 in·lb)
Tighten the upper crankcase bolts.
Torque:
Crankcase 7 mm Bolts [A]: 20 N·m (2.0 kg·m, 14.5 ft·lb)
Crankcase 6 mm Bolts [B]: 12 N·m (1.2 kg·m, 104 in·lb)
After tightening all crankcase bolts, check the following items.
Crankshaft and transmission shafts turn freely.
While spinning the output shaft, gears shift smoothly from the 1st to 6th gear, and 6th to 1 st.
When the output shaft stays still, the gear can not be shifted to 2nd gear or other higher gear positions.