Sealant - Kawasaki Bond (Silicone Sealant): 56019-120

Torque - Oil Pressure Switch: 15 N·m (1.5 kgf·m, 11 ft·lb)

• Tighten the terminal bolt securely.

• Apply a small amount grease to the terminal so that

grease should not close two breather holes [A] for switch

diaphragm.

 

 

 

 

 

Engine Removal/Installation

Table of Contents

Exploded View........................................................................................................................ 8-2

Engine Removal/Installation................................................................................................... 8-4

Engine Removal................................................................................................................ 8-4

Engine Installation............................................................................................................. 8-7

 

 

8

 

Exploded View

 

Exploded View

No.	Fastener	Torque	Remarks
N·m	kgf·m	ft·lb
	Rear Engine Mounting Nuts		4.5		S
	Front Engine Mounting Bolts		4.5		S
	Engine Mounting Bracket Bolts		2.5		S

4. Engine Mounting Brackets

5. Collar

S: Follow the specified tightening sequence.

 

Engine Removal

• Support the rear part of the swingarm with a stand.

• Squeeze the brake lever slowly and hold it with a band

WARNING

Be sure to hold the front brake when removing the engine, or the motorcycle may fall over. It could cause an accident and injury.

[A].

 

CAUTION

Be sure to hold the front brake when removing the engine, or the motorcycle may fall over. The engine or the motorcycle could be damaged.

• Drain:

Engine Oil (see Engine Oil Change in the Periodic Main-

tenance chapter)

Coolant (see Coolant Change in the Periodic Mainte- nance chapter)

• Remove:

Seat (see Seat Removal in the Frame chapter)

Lower Fairings (see Lower Fairing Removal in the Frame chapter)

Upper Inner Fairings (see Upper Inner Fairing Removal in the Frame chapter)

Windshield (see Windshield Removal in the Frame chapter)

Meter Cover (see Meter Unit Removal/Installation in the Electrical System chapter)

Center Fairings (see Center Fairing Removal in the Frame chapter)

Side Covers (see Side Cover Removal in the Frame chapter)

Frame Covers (see Frame Cover Removal in the Frame chapter)

Radiator and Hoses (see Radiator and Radiator Fan Re- moval in the Cooling System chapter)

• Pull the clamp [A] on the lower fairing bracket.

• Unscrew the lower fairing bracket bolts (both sides) [B]

and remove the brackets (both sides) [C].

• Disconnect the oil pressure switch terminal [D].

 

• Disconnect the crankshaft sensor lead connector [A].

 

 

• Remove:

Exhaust Pipe (see Exhaust Pipe Removal in the Engine

Top End chapter)

Muffler Body (see Muffler Body Removal in the Engine Top End chapter)

Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter)

Air Switching Valve and Hose (see Air Switching Valve Removal in the Engine Top End chapter)

Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter)

Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter)

Clutch Cable (see Clutch Cable Removal in the Clutch chapter)

• Remove:

Stick Coils [A]

Baffle Plate [B] Hose [C]

 

 

• Remove or Disconnect:

Water Temperature Sensor Lead Connector [A]

Starter Motor Cable [B]

Engine Ground Cable Terminal Bolt [C] Alternator Lead Connector [D] Sidestand Switch Lead Connector [E] Speed Sensor Lead Connector [F]

 

 

• Remove the engine sprocket cover (see Engine Sprocket Removal in the Final Drive chapter).

• Remove the shift pedal [A] (see Shift Pedal Removal in

the Crankshaft/Transmission chapter).

• Disconnect:

Oxygen Sensor Lead Connector [B] (Europe Models)

Neutral Switch Lead Terminal [C]

• Remove the bracket [D] and the engine sprocket [E] (see Engine Sprocket Removal in the Final Drive chapter).

 

• Support the engine with a stand or jack [A].

○Put a wooden board [B] on the suitable stand.

• Remove the engine mounting bolts [C].

• Remove the engine mounting bracket bolts (both sides)

[D] and remove the brackets [E].

• Remove the engine [F].

 

 

Engine Installation

• Firstly, insert the rear engine mounting bolts [A] from the left side of the engine.

• Secondly, temporally tighten the right engine mounting

bracket bolts [B] and then the right front engine mounting

bolt [C].

○Position the collar [D] as shown.

• Thirdly, temporally tighten the left engine mounting bracket bolts [E] and then the left front engine mounting

bolt [F].

• Fourthly, temporally tighten the rear engine mounting nuts [G].

• Fifthly, tighten the rear engine mounting nuts.

Torque - Rear Engine Mounting Nuts: 44 N·m (4.5 kgf·m, 32

ft·lb)

• Sixthly, tighten the right engine mounting bracket bolts.

Torque - Engine Mounting Bracket Bolts: 25 N·m (2.5

kgf·m, 18 ft·lb)

• Seventhly, tighten the right front engine mounting bolt.

Torque - Front Engine Mounting Bolt: 44 N·m (4.5 kgf·m, 32

ft·lb)

• Eighthly, tighten the left engine mounting bracket bolts.

Torque - Engine Mounting Bracket Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)

• Lastly, tighten the left front engine mounting bolt.

Torque - Front Engine Mounting Bolt: 44 N·m (4.5 kgf·m, 32 ft·lb)

• Install the engine sprocket (see Engine Sprocket Installa-

tion in the Final Drive chapter).

• Run the leads, cables, and hoses correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter).

• Install the removed parts (see appropriate chapters).

• Adjust:

Throttle Cables (see Throttle Control System Inspection

in the Periodic Maintenance chapter)

Clutch Cable (see Clutch Operation Inspection in the Pe- riodic Maintenance chapter)

Drive Chain (see Drive Chain Slack Adjustment in the Periodic Maintenance chapter)

• Fill the engine with engine oil (see Engine Oil Change in

the Periodic Maintenance chapter).

• Fill the engine with coolant and bleed the air from the cool- ing system (see Coolant Change in the Periodic Mainte-

nance chapter).

• Adjust the idling (see Idle Speed Adjustment in the Peri- odic Maintenance chapter).

 

 

 

 

 

Crankshaft/Transmission

Table of Contents

Exploded View........................................................................................................................ 9-2

Specifications......................................................................................................................... 9-6

Special Tools and Sealant...................................................................................................... 9-9

Crankcase Splitting................................................................................................................. 9-10

Crankcase Splitting........................................................................................................... 9-10

Crankcase Assembly........................................................................................................ 9-11

Crankshaft and Connecting Rods........................................................................................... 9-17

Crankshaft Removal......................................................................................................... 9-17

Crankshaft Installation...................................................................................................... 9-17

Connecting Rod Removal................................................................................................. 9-17

Connecting Rod Installation.............................................................................................. 9-18

Crankshaft/Connecting Rod Cleaning............................................................................... 9-21

Connecting Rod Bend....................................................................................................... 9-21

Connecting Rod Twist....................................................................................................... 9-22

Connecting Rod Big End Side Clearance......................................................................... 9-22

Connecting Rod Big End Bearing Insert/Crankpin Wear.................................................. 9-22

Crankshaft Side Clearance............................................................................................... 9-24

Crankshaft Runout............................................................................................................ 9-24

Crankshaft Main Bearing Insert/Journal Wear.................................................................. 9-24

Balancer................................................................................................................................. 9-27

Balancer Removal............................................................................................................. 9-27

Balancer Installation.......................................................................................................... 9-27

Balancer Shaft Bearing Insert/Journal Clearance............................................................. 9-27

Transmission.......................................................................................................................... 9-29

Shift Pedal Removal......................................................................................................... 9-29

Shift Pedal Installation...................................................................................................... 9-29

External Shift Mechanism Removal.................................................................................. 9-29

External Shift Mechanism Installation............................................................................... 9-30

External Shift Mechanism Inspection................................................................................ 9-31

Transmission Assy Removal............................................................................................. 9-32

Transmission Assy Disassembly...................................................................................... 9-33

Transmission Assy Assembly........................................................................................... 9-33

Transmission Assy Installation.......................................................................................... 9-34

Transmission Shaft Removal............................................................................................ 9-35

Transmission Shaft Installation......................................................................................... 9-35

Transmission Shaft Disassembly...................................................................................... 9-36

Transmission Shaft Assembly........................................................................................... 9-36

Shift Drum and Fork Removal........................................................................................... 9-39

Shift Drum and Fork Installation........................................................................................ 9-39

Shift Drum Disassembly.................................................................................................... 9-39

Shift Drum Assembly........................................................................................................ 9-39

Shift Fork Bending............................................................................................................ 9-39

Shift Fork/Gear Groove Wear........................................................................................... 9-39

Shift Fork Guide Pin/Drum Groove Wear.......................................................................... 9-40

Gear Dog and Gear Dog Hole Damage............................................................................ 9-40

Ball Bearing, Needle Bearing, and Oil Seal............................................................................ 9-41

Ball and Needle Bearing Replacement............................................................................. 9-41

Ball and Needle Bearing Wear.......................................................................................... 9-41

Oil Seal Inspection............................................................................................................ 9-41

 

 

 

 

No.	Fastener	Torque	Remarks
N·m	kgf·m	ft·lb
	Connecting Rod Big End Nuts	see Text	←	←	MO
	Timing Rotor Bolt		4.1
	Oil Plate Bolts	9.8	1.0	87 in·lb	L
	Breather Plate Bolts	9.8	1.0	87 in·lb	L
	Shift Shaft Return Spring Pin		2.9		L
	Oil Pipe Bolts	9.8	1.0	87 in·lb	L
	Crankcase Bolts (M9, L = 113 mm)		4.5		MO, S
	Crankcase Bolts (M9, L = 83 mm)		4.5		MO, S
	Crankcase Bolts (M8, L = 73 mm)		3.6		MO, S
	Crankcase Bolts (M8, L = 60 mm)		3.6		MO, S
	Crankcase Bolts (M8, L = 110 mm)	27.5	2.8		S
	Crankcase Bolts (M8, L = 50 mm)	27.5	2.8		S
	Crankcase Bolts (M6)	19.6	2.0		S
	Upper Crankcase Bolts	27.5	2.8		S

15. Do not apply any grease or oil. G: Apply grease.

L: Apply a non-permanent locking agent. LG: Apply liquid gasket.

M: Apply molybdenum disulfide grease. MO: Apply molybdenum disulfide oil solution.

(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10: 1) R: Replacement Parts

S: Follow the specified tightening sequence. SS: Apply silicone sealant.

 

 

 

 

 

No.	Fastener	Torque	Remarks
N·m	kgf·m	ft·lb
	Gear Positioning Lever Bolt		1.2	106 in·lb	L
	Transmission Case Bolts		2.0
	Shift Drum Cam Bolt		1.2	106 in·lb	L
	Shift Drum Bearing Holder Screw	4.9	0.50	43 in·lb	L
	Shift Rod Plate Bolt	9.8	1.0	87 in·lb
	Neutral Switch Holder Screw	4.9	0.50	43 in·lb	L
	Neutral Switch		1.5
	Shift Shaft Cover Bolts	9.8	1.0	87 in·lb	L (2)
	Shift Shaft Cover Screw	4.9	0.50	43 in·lb	L

EO: Apply engine oil. G: Apply grease.

L: Apply a non-permanent locking agent. MO: Apply molybdenum disulfide oil solution.

(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10: 1) R: Replacement Parts

Con-rod Big End Bore Diameter Marking Crankpin Diameter Marking Bearing Insert Size Color Part Number None ○ Brown 92139-0116 None None Black 92139-0115 ○ ○ ○ None Blue 92139-0114

 

Item	Standard	Service Limit
Crankshaft, Connecting Rods Connecting Rod Bend Connecting Rod Twist Connecting Rod Big End Side Clearance   Connecting Rod Big End Bearing Insert/Crankpin Clearance Crankpin Diameter:   Marking: None ○ Connecting Rod Big End Inside Diameter: Marking: None   ○ Connecting Rod Big End Bearing Insert Thickness: Brown   Black Blue	– – –	TIR 0.2/100 mm
	(0.008/3.94 in.)
– – –	TIR 0.2/100 mm
	(0.008/3.94 in.)
0.13 ~ 0.38 mm	0.58 mm
(0.0051 ~ 0.0150 in.)	(0.023 in.)
0.017 ~ 0.041 mm	0.08 mm
(0.0007 ~ 0.0016 in.)	(0.0031 in.)
37.984 ~ 38.000 mm	37.97 mm
(1.4954 ~ 1.4961 in.)	(1.4949 in.)
37.984 ~ 37.992 mm	– – –
(1.4954 ~ 1.4957 in.)
37.993 ~ 38.000 mm	– – –
(1.4958 ~ 1.4961 in.)
41.000 ~ 41.016 mm	– – –
(1.6142 ~ 1.6148 in.)
41.000 ~ 41.008 mm	– – –
(1.6142 ~ 1.6145 in.)
41.009 ~ 41.016 mm	– – –
(1.6145 ~ 1.6148 in.)
1.475 ~ 1.480 mm	– – –
(0.05807 ~ 0.05827 in.)
1.480 ~ 1.485 mm	– – –
(0.05827 ~ 0.05846 in.)
1.485 ~ 1.490 mm	– – –
(0.05846 ~ 0.05866 in.)
Connecting Rod Big End Bearing Insert Selection:
Connecting Rod Bolt Stretch: (Usable Range)
New Connecting Rod	0.24 ~ 0.36 mm	– – –
	(0.0094 ~ 0.0142 in.)
Used Connecting Rod	0.20 ~ 0.32 mm (0.0079 ~ 0.0126 in.)	– – –
Crankshaft Side Clearance	0.05 ~ 0.20 mm	0.40 mm
	(0.0020 ~ 0.0079 in.)	(0.0157 in.)

Crankcase Main Bearing Inside Diameter Marking Crankshaft Main Journal Diameter Marking Bearing Insert* Size Color Part Number ○   Brown 92028-1905 None   Black 92028-1904 ○ None None None Blue 92028-1903

 

Specifications

Item	Standard	Service Limit
Crankshaft Runout Crankshaft Main Bearing Insert/Journal Clearance Crankshaft Main Journal Diameter: Marking: None Crankcase Main Bearing Inside Diameter: Marking: ○ None Crankshaft Main Bearing Insert Thickness: Brown Black Blue	TIR 0.02 mm (0.0008 in.)	TIR 0.05 mm
or less	(0.0020 in.)
0.012 ~ 0.036 mm	0.07 mm
(0.0005 ~ 0.0014 in.)	(0.0028 in.)
37.984 ~ 38.000 mm	37.96 mm
(1.4954 ~ 1.4961 in.)	(1.4945 in.)
37.984 ~ 37.992 mm	– – –
(1.4954 ~ 1.4957 in.)
37.993 ~ 38.000 mm	– – –
(1.4958 ~ 1.4961 in.)
41.000 ~ 41.016 mm	– – –
(1.6142 ~ 1.6148 in.)
41.000 ~ 41.008 mm	– – –
(1.6142 ~ 1.6145 in.)
41.009 ~ 41.016 mm	– – –
(1.6145 ~ 1.6148 in.)
1.490 ~ 1.494 mm	– – –
(0.0587 ~ 0.0588 in.)
1.494 ~ 1.498 mm	– – –
(0.0588 ~ 0.0590 in.)
1.498 ~ 1.502 mm	– – –
(0.0590 ~ 0.0591 in.)
Crankshaft Main Bearing Insert Selection: *The bearing inserts for Nos. 1, 2 and 3 journals have oil grooves.
Balancer Shaft Balancer Shaft Bearing Insert/Journal Clearance Balancer Shaft Journal Diameter: Marking: None ○	0.011 ~ 0.033 mm	0.08 mm
(0.0004 ~ 0.0013 in.)	(0.0031 in.)
27.987 ~ 28.000 mm	27.96 mm
(1.1019 ~ 1.1024 in.)	(1.1108 in.)
27.987 ~ 27.993 mm (1.1019 ~ 1.1021 in.)	– – –
27.994 ~ 28.000 mm (1.1021 ~ 1.1024 in.)	– – –

Crankcase Bearing Bore Diameter Marking Balancer Shaft Journal Diameter Marking Bearing Insert* Size Color Part Number ○ ○ Brown 92139-0119 ○ None   Black   92139-0118 None ○ None None Blue 92139-0117

 

 

Item	Standard	Service Limit
Crankcase Bearing Bore Diameter:	31.000 ~ 31.016 mm (1.2205 ~ 1.2228 in.)	– – –
Marking:
○	31.000 ~ 31.008 mm (1.2205 ~ 1.2208 in.)	– – –
None	31.009 ~ 31.016 mm (1.2208 ~ 1.2211 in.)	– – –
Balancer Shaft Bearing Insert Thickness:
Brown	1.490 ~ 1.494 mm (0.0587 ~ 0.0588 in.)	– – –
Black	1.494 ~ 1.498 mm (0.0588 ~ 0.0590 in.)	– – –
Blue	1.498 ~ 1.502 mm (0.0590 ~ 0.0591 in.)	– – –
Balancer Shaft Bearing Insert Selection:   *The bearing inserts for Nos. 1,2 journals have oil grooves.
Transmission
Shift Fork Ear Thickness	5.9 ~ 6.0 mm	5.8 mm
	(0.232 ~ 0.236 in.)	(0.228 in.)
Gear Groove Width	6.05 ~ 6.15 mm	6.25 mm
	(0.238 ~ 0.242 in.)	(0.246 in.)
Shift Fork Guide Pin Diameter	6.9 ~ 7.0 mm	6.8 mm
	(0.272 ~ 0.276 in.)	(0.268 in.)
Shift Drum Groove Width	7.05 ~ 7.20 mm	7.3 mm
	(0.278 ~ 0.283 in.)	(0.287 in.)

 

 

Special Tools and Sealant

Outside Circlip Pliers: 57001-144

Kawasaki Bond: 92104-1064

Bearing Driver Set: 57001-1129

 

Crankcase Splitting

• Remove:

Engine (see Engine Removal in the Engine Removal/In-

stallation chapter)

Cylinder (see Cylinder Removal in the Engine Top End chapter)

Pistons (see Piston Removal in the Engine Top End chapter)

Stater Motor (see Starter Motor Removal in the Electrical System chapter)

Clutch (see Clutch Removal in the Clutch chapter) Transmission Assy (see Transmission Assy Removal) Alternator Rotor (see Alternator Rotor Removal in the Electrical System chapter)

• Remove the upper crankcase bolts [A] and the washers.

 

 

• Remove the oil pan, relief valve, oil screen and oil pipes (see Oil Pan Removal in the Engine Lubrication System

chapter).

• Remove the lower crankcase bolts.

○Firstly loosen the M6 bolts, secondly the M8 bolts and

lastly the M9 bolts.

M6 Bolts [A] M8 Bolts [B]

M9 Bolts [C] and Washers

• Tap lightly around the crankcase mating surface with a plastic mallet, and split the crankcase. Take care not to

damage the crankcase.

 

If the oil pipe is to be removed, follow the next procedure.

○Unscrew the bolts [A] and remove the oil pipe [B].

 

○Preparea 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.

 

 

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

 

CAUTION

The upper and lower crankcase halves are ma- chined at the factory in the assembled state, so the crankcase halves must be replaced as a set.

Crankcase Assembly

• With a high-flash point solvent, clean off the mating sur- faces 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 re- moved, install it as shown.

• Apply a non-permanent locking agent to the oil plate bolts

and torque them.

Torque - Oil Plate Bolts [B]: 9.8 N·m (1.0 N·m, 87 in·lb)

 

• Press and insert [A] the new needle bearing [B] for the shift drum until it is bottomed.