92028-1692 Crankcase

Bearing Bore

Diameter

Marking

Balancer

Shaft Journal

Diameter

Marking

Size Color

Brown

Bearing Insert*

Part Number

L. H.

R. H.

92028-1497

None

None

Black

92028-1496

92028-1691

None

None

Blue

92028-1495

92028-1690

Transmission

Gear Shift Fork Groove Width

Shift Fork Ear Thickness Shift Fork Guide Pin Diameter Shift Fork Dowel Pin Diameter Shift Drum Groove Width

5.05 ∼ 5.15 mm (0.1988 ∼ 0.2028 in.)

4.9 ∼ 5.0 mm (0.193 ∼ 0.197 in.)

7.900 ∼ 8.000 mm (0.3110 ∼ 3150 in.)

7.985 ∼ 8.000 mm (0.3144 ∼ 0.3150 in.)

8.05 ∼ 8.20 mm (0.3169 ∼ 0.3228 in.)

5.3 mm (0.2087 in.)

4.8 mm (0.189 in.)

7.8 mm (0.307 in.)

7.8 mm (0.307 in.)

8.3 mm (0.327 in.)

*: The bearing inserts for Nos. 2 and 3 journals have oil grooves.

CRANKSHAFT/TRANSMISSION 9-9

Special Tools and Sealant

Bearing Puller: 57001-135

Bearing Driver, ф32: 57001-382

Outside Circlip Pliers: 57001-144

Kawasaki Bond (Silicone Sealant): 56019-120

Bearing Puller Adapter: 57001-317

Kawasaki Bond (Liquid Gasket - Gray): 92104-1063

9-10 CRANKSHAFT/TRANSMISSION

Crankcase Splitting

Crankcase Splitting

• Remove the engine (see Engine Removal in the Engine Removal/Installation chapter).

• Set the engine on a clean surface and hold the engine steady while parts are being removed.

• Remove:

Shift Pedal Link Lever

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

Water Pump (see Water Pump Removal in the Cooling System chapter)

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

• Remove the following parts only if the crankshaft is to be removed.

Cylinder Head, Cylinder and Pistons (see Cylinder Head, Cylinder and Piston Removal in the Engine Top End chapter)

Starter Clutch Sprocket (see Starter Clutch Sprocket Re­moval in the Electrical System chapter) Clutch (see Clutch Removal in the Clutch chapter)

• Remove the 6 mm upper crankcase-half bolts [A], [B] first, and then the 8 mm bolt [C].

○Remove the 6 mm upper crankcase-half bolts [A] before installing the engine to the engine equipment.

• Turn the engine upside down and remove the following parts:

Oil Pan (see Oil Pan Removal in the Engine Lubrication System chapter)

Oil Pump Outer Pipe (see Oil Pump Removal in the En­gine Lubrication System chapter)

• Remove the 6 mm lower crankcase-half bolts [A] first, and then the 8 mm bolts [B] in the reverse order of installation sequence (see Crankcase Assembly).

• Pull the breather return pipe out of the crankcase and leave it in place temporarily.

CRANKSHAFT/TRANSMISSION 9-11

Crankcase Splitting

• Pry the points [A] indicated in the figure to split the crankcase halves apart, and remove the lower crankcase half. There are two knock pins at the front and rear of the cases.

Crankcase Assembly