9-10 CRANKSHAFT/TRANSMISSION

Crankcase Splitting

Crankcase• Splitting

Remove the engine (see Engine Removal/Installation

•chapter).

Set the engine on a clean surface and hold the engine

•steady while parts are being removed. Remove:

Crankshaft Sensor (see Electrical System chapter) Clutch (see Clutch chapter)

External Shift Mechanism (see External Shift Mechanism Removal)

Starter Motor (see Electrical System chapter)

Oil Pump (see Engine Lubrication System chapter) Alternator Rotor (see Electrical System chapter) Oil Filter (see Engine Lubrication System chapter)

If the crankshaft is to be removed, remove the pistons (see Engine Top End chapter).

•Remove the upper crankcase bolts. ○First loosen the M6 bolts.

M6 Bolts [A]

M7 Bolts [B]

M8 Bolts [C]

•Remove the oil pan, relief valve, oil screen and oil pipes

•(see Engine Lubrication System chapter). Remove the lower crankcase bolts.

○First loosen the M7 bolts. M7 Bolts [A]

• M9 Bolts [B]

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

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 sur-

•faces of the crankcases halves and wipe dry.

Using compressed air, blow out the oil passages in the crankcase halves.

CRANKSHAFT/TRANSMISSION 9-11

Crankcase Splitting

•Apply liquid gasket to the breather plate mating surface [A] 1 to 1.5 mm (0.04 to 0.06 in.) thick, and then install the breather plate.

Sealant - Three Bond: 1207B

•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)

•Install the breather hose [A].

○Align the white mark on the hose with the white mark on the pipe.

○Install the clamp [B] so that its head faces to right side. Breather Plate [C]

•Install:Crankshaft and Connecting Rods

Camshaft Chain [A]

Transmission Shafts 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.

9-12 CRANKSHAFT/TRANSMISSION

Crankcase Splitting

•Apply liquid gasket [A] to the mating surface of the lower crankcase half.

Sealant - Kawasaki Bond (Silicone Sealant): 92104–1066

CAUTION

Do not apply liquid gasket around the crankshaft main bearing inserts, and oil passage holes.

•Fit the lower crankcase to the upper crankcase.

•Apply molybdenum disulfide oil to the seating surface [A] on the lower crankcase for the M9 bolts [B].

Washer [C]

•Tightensteps. the lower crankcase bolts using the following ○Following the sequence numbers on the lower crankcase half, tighten the M9 bolts [1 6] L= 81 mm (3.19 in.).

Torque - Crankcase Bolts (M9): 42 N·m (4.3 kgf·m, 31 ft·lb)

○Tighten the M9 bolts [7 10] L= 95 mm (3.74 in.) with washers.

Torque - Crankcase Bolts (M9): 42 N·m (4.3 kgf·m, 31 ft·lb)

○Tighten the M7 bolts [A].

Torque - Crankcase Bolts (M7): 20 N·m (2.0 kgf·m, 14 ft·lb)

•Tighten the upper crankcase bolts in the order listed.

Torque - Crankcase Bolts (M8) [A]: 27 N·m (2.8 kgf·m, 20 ft·lb)

Crankcase Bolts (M7): 20 N·m (2.0 kgf·m, 14 ft·lb)

L= 85 mm (3.35 in.) [B] L= 50 mm (1.97 in.) [C]

Crankcase Bolts (M6): 12 N·m (1.2 kgf·m, 104 in·lb)

L= 60 mm (2.36 in.) [D] L= 40 mm (1.57 in.) [E] L= 90 mm (3.54 in.) [F]

Clamp [G]

•Afteritems.tightening all crankcase bolts, check the following ○Crankshaft and transmission shafts turn freely.

○While spinning the output shaft, gears shift smoothly from the 1st to 6th gear, and 6th to 1st.

○When the output shaft stays still, the gear can not be shifted to 2nd gear or other higher gear positions.

CRANKSHAFT/TRANSMISSION 9-13

Crankshaft and Connecting Rods

Crankshaft• Removal

•Split the crankcase (see Crankcase Splitting). Remove the crankshaft [A].

Crankshaft Installation

CAUTION

If the crankshaft, bearing inserts, or crankcase halves are replaced with new ones, select the bearing inserts and check clearance with a plastigage (press gauge) before assembling engine to be sure the correct bearing inserts are installed.

•Apply molybdenum disulfide oil solution to the crankshaft

•main bearing inserts.

Install the crankshaft with the camshaft chain [A] hanging on it.

Connecting• Rod Removal

•Split the crankcase (see Crankcase Splitting).

•Remove the connecting rod nuts [A]. Remove the crankshaft.

NOTE

○Mark and record the locations of the connecting rods and their big end caps so that they can be reassembled in their original positions.

•Remove the connecting rods from the crankshaft.

CAUTION

Discard the connecting rod bolts. To prevent damage to the crankpin surfaces, do not allow the connecting rod bolts to bump against the crankpins.

Connecting Rod Installation

CAUTION

To minimize vibration, the connecting rods should have the same weight mark.

Big End Cap [A]

Connecting Rod [B]

Weight Mark, Alphabet [C]

Diameter Mark [D]: “ ” or no mark

CAUTION

If the connecting rods, big end bearing inserts, or crankshaft are replaced with new ones, select the bearing insert and check clearance with a plastigage (press gauge) before assembling engine to be sure the correct bearing inserts are installed.

9-14 CRANKSHAFT/TRANSMISSION

Crankshaft and Connecting Rods

•Apply molybdenum disulfide grease [A] to the outer surface of the upper insert and the inner surface of the con-

•necting rod big end.

Apply molybdenum disulfide oil [B] to the inner surfaces of upper and lower bearing inserts.

○The molybdenum disulfide oil is a mixture of engine oil and molybdenum disulfide grease with a weight ratio (10:1).

○Do not apply any grease or oil [C] to the cap inside and cap insert outside.

○Install the inserts so that their nails [D] are on the same side and fit them into the recess of the connecting rod and cap.

CAUTION

Wrong application of oil and grease could cause bearing damage.

○When installing the inserts [A], be careful not to damage the insert surface with the edge of the connecting rod [B] or the cap [C]. One way to install inserts is as follows:

Installation [D] to Cap

Installation [E] to Connecting Rod

Push [F]

Spare Dowel Pin [G]

• Connecting Rod Bolts [H]

Install the cap on the connecting rod, aligning the weight

•and diameter marks.

•Remove debris and clean the surface of inserts.

Apply molybdenum disulfide oil [MO] to the threads and seating surfaces of the big end nuts and bolts.

•Install the crankshaft (see Crankshaft Installation).

•Install each connecting rod on its original crankpin. ○The connecting rod big end is bolted using the “plastic

region fastening method”.

○This method precisely achieves the needed clamping force without exceeding it unnecessarily, allowing the use of thinner, lighter bolts further decreasing connecting rod weight.

○There are two types of the plastic region fastening. One is a bolt length measurement method and other is a rotation angle method. Observe one of the following two, but the bolt length measurement method is preferable because this is a more reliable way to tighten the big end nuts.

CAUTION

The connecting rod bolts are designed to stretch when tightened. Never reuse the connecting rod bolts. See the table below for correct bolt and nut usage.

CAUTION

Be careful not to overtighten the nuts.

The bolts must be positioned on the seating surface correctly to prevent the bolt heads from hitting the crankcase.

CRANKSHAFT/TRANSMISSION 9-15

Crankshaft and Connecting Rods

(1)• Bolt Length Measurement Method

Be sure to clean the bolts, nuts, and connecting rods thoroughly with a high-flash point solvent, because the new connecting rods, bolts, and nuts are treated with an anti-rust solution.

WARNING

Clean the bolts, nuts, and connecting rods in a well -ventilated area, and take care that there is no spark or flame anywhere near the working area. This includes any appliance with a pilot light. Because of the danger of highly flammable liquids, do not use gasoline or low-flash point solvents to clean them.

CAUTION

Immediately dry the bolts and nuts with compressed air after cleaning.

Clean and dry the bolts and nuts completely.

9-16 CRANKSHAFT/TRANSMISSION

Crankshaft and Connecting Rods

(2) Rotation Angle Method

If you don’t have a point micrometer, you may tighten the

•nuts using the “Rotation Angle Method”.

Be sure to clean the bolts and nuts thoroughly with a high -flash point solvent, because the new bolts and nuts are treated with an anti-rust solution.

WARNING

Clean the bolts and nuts in a well-ventilated area, and take care that there is no spark or flame anywhere near the working area. This includes any appliance with a pilot light. Because of the danger or highly flammable liquids, do not use gasoline or low-flash point solvents to clean them.

CAUTION

Immediately dry the bolts and nuts with compressed air after cleaning.

Clean and dry the bolts and nuts completely.

•Install new bolts in reused connecting rods.

•Apply a small amount of molybdenum disulfide oil to the following:

Threads [A] of Nuts and Bolts

Seating Surfaces [B] of Nuts and Con-rods

Crankshaft/Connecting• Rod Cleaning

After removing the connecting rods from the crankshaft,

•clean them with a high-flash point solvent.

Blow the crankshaft oil passages with compressed air to remove any foreign particles or residue that may have accumulated in the passages.