Table of Contents

Exploded View 9-2

Specifications 9-6

Special Tools and Sealant 9-8

Crankcase Splitting 9-9

Crankcase Splitting 9-9

Crankcase Assembly 9-9

Crankshaft and Connecting Rods 9-12

Crankshaft Removal 9-12

Crankshaft Installation 9-12

Connecting Rod Removal 9-12

Connecting Rod Installation 9-12

Crankshaft/Connecting Rod

Cleaning 9-15

Connecting Rod Bend 9-16

Connecting Rod Twist 9-16

Connecting Rod Big End Side

Clearance 9-16

Connecting Rod Big End Bearing

Insert/Crankpin Wear 9-17

Crankshaft Side Clearance 9-18

Crankshaft Runout 9-18

Crankshaft Main Bearing

Insert/Journal Wear 9-19

Starter Motor Clutch 9-21

Starter Motor Clutch

Removal/Installation 9-21

Starter Motor Clutch Assembly 9-21

Starter Motor Clutch Inspection ... 9-21

Transmission 9-22

Shift Pedal Removal 9-22

Shift Pedal Installation 9-22

External Shift Mechanism

Removal 9-23

External Shift Mechanism

Installation 9-24

External Shift Mechanism

Inspection 9-24

Transmission Shaft Removal 9-25

Transmission Shaft Installation 9-25

Transmission Shaft Disassembly. 9-25

Transmission Shaft Assembly 9-26

Shift Drum and Fork Removal 9-28

Shift Drum and Fork Installation... 9-29

Shift Drum Disassembly 9-29

Shift Drum Assembly 9-29

Shift Fork Bending 9-29

Shift Fork/Gear Groove Wear 9-30

Shift Fork Guide Pin/Drum

Groove Wear 9-30

Gear Dog and Gear Dog Hole

Damage 9-30

Exploded View

No.

Fastener

Torque

Remarks

N-m

kgfm

ftlb

1

Breather plate bolts

10

1.0

87 inlb

L

2

Crankcase bolts (M9, L=81 mm)

42

4.3

31

MO,S

3

Crankcase bolts (M9, L=95 mm)

49

5.0

36

MO,S

4

Crankcase bolts (M8)

27

2.8

20

S

5

Crankcase bolts (M7)

20

2.0

14.5

S

6

Crankcase bolts (M6)

12

1.2

104 in lb

S

7

Starter motor clutch bolts

12

1.2

104 in lb

L

8

Oil pipe holder bolts

13

1.3

113 in lb

L

9

Shift drum bearing holder screw

5.4

0.55

48 in lb

L

10

Shift drum bearing holder bolt

13

1.3

113 in lb

L

11

Connecting rod big end nuts

see the text

——

——

——

12

Crankshaft position rotor bolt

40

4.0

29

13

Oil pressure switch

15

1.5

11

SS

14

Oil pressure switch terminal bolt

1.5

0.15

13 in lb

15

Oil passage plugs

20

2.0

14.5

L

16

Crankshaft sensor cover bolts

11

1.1

95 in lb

17. Do not apply any grease or oil. EO: Apply engine oil. G: Apply grease.

L: Apply a non-permanent locking agent. LG: Apply liquid gasket (Kawasaki Bond: 92104-1063). M: Apply molybdenum disulfide grease. MO: Apply molybdenum disulfide oil.

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

S: Tightening the fasteners following the specified sequence. SS: Apply silicone sealant (Kawasaki Bond: 56019-120).

Exploded View

No.

Fastener

Torque

Remarks

Nm

kgfm

ftlb

1

Shift pedal mounting bolt

34

3.5

25

L

2

Gear positioning lever bolt

12

1.2

104 inlb

3

Shift shaft return spring pin

29

3.0

22

L

4

Shift drum cam holder bolt

12

1.2

104 in lb

L

5

Footpeg bracket bolts

34

3.5

25

L

6

Shift lever bolt

6.9

0.7

61 inlb

7

Tie-rod locknuts

6.9

0.7

61 inlb

8

Neutral switch

15

1.5

11

EO: Apply engine oil. G: Apply grease.

L: Apply a non-permanent locking agent. R: Replacement Parts

EO: Apply engine oil. G: Apply grease.

L: Apply a non-permanent locking agent. R: Replacement Parts

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