Caution

The upper crankcase half and the lower crankcase half are machined at the factory in the assembled state, so the crankcase halves must be replaced to­gether as a set.

• 

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

• With a high flash-point solvent, clean off the mating sur­faces of the crankcase halves and wipe dry.

• Before fitting the lower case on the upper case, check the following.

○Check to see that the following parts are in place on the upper crankcase half. Knock Pins [A] Crankshaft Assembly [B] Balancer Shaft Assembly [C] Drive Shaft Assembly and Clutch Housing [D] Output Shaft Assembly [E] ○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 (Liquid Gasket - Gray): 92104 -1063

Caution

Do not apply liquid gasket around the crankshaft main bearing inserts and balancer shaft inserts.

9-12 CRANKSHAFT/TRANSMISSION

Crankcase Splitting

• Fit the lower crankcase half on the upper crankcase half

observing the following. ○Set the shift forks so that the ears [A] of each fork fit into

the grooves of the gears.

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• Tighten the lower crankcase-half bolts using the following 3 steps:

OTighten all lower crankcase-half bolts to a snug fit. Following the sequence numbers on the lower crankcase half, torque the 8 mm bolts first to about one half of the specification, and finally to the specification in the same sequence.

Torque Value for 8 mm Bolts

First 14 N-m (1.4 kgf-m, 10.0 ft-lb)

Final 27 N-m (2.8 kgf-m, 20 ft-lb)

OTighten the 6 mm bolts.

Torque - Crankcase 6 mm Bolts: 12 N-m (1.2 kgf-m, 104 in-lb)

• Check that the O-ring [A] of the breather return pipe is in good condition.

• If it is damaged, replace it with a new one.

• Apply a small amount of oil to the O-ring.

• Fit the breather return pipe [B] into the passage in the upper crankcase half.

• Install the main oil pipe connecting pipe [A] and oil pump outer pipe [B].

OCheck that the O-rings are in good condition.

• If they are damaged, replace them with new ones. OApply a small amount of oil to the O-rings. The positioning

hole in the connecting pipe must fit to the boss on the lower case. OApply a non-permanent locking agent to the threads of the oil outer pipe mounting bolt.

• Install the oil screen.

• Install the oil pan (see Oil Pan Installation in the Engine Lubrication System chapter).

CRANKSHAFT/TRANSMISSION 9-13

Crankcase Splitting

• 

  Turn the engine over so it is upright.

• Put the 8 mm bolts [A], and the 6 mm bolts [B] into the upper crankcase half as shown in the figure, torque the 8 mm bolt first, then the other bolts in the sequence shown.

Torque - Crankcase 8 mm Bolts: 27 N-m (2.8 kgf-m, 20 ft-lb) Crankcase 6 mm Bolts: 12 N-m (1.2 kgf-m, 104 in-lb)

• After tightening all crankcase bolts, check the following items:

ODrive shaft and output shaft turn freely.

OWhile spinning the output shaft, gears shift smoothly from

the 1st to 6th gear, and 6th to 1st. OWhen the output shaft stays still, the gear can not be

shifted to 2nd gear or other higher gear positions.

9-14 CRANKSHAFT/TRANSMISSION

Clutch Housing/Primary Chain

Clutch Housing/Primary Chain Removal

• Remove the engine.

• Remove:

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

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

• Split the crankcase.

• Lift up the transmission drive shaft assembly [A], and pull the shaft out of the clutch housing [B].

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• Place the clutch housing on the balancer drive gear, slack off the primary chain [A] as much as possible and slip the primary chain off the clutch housing sprocket [B].

• Remove the clutch housing [A].

• Pull off the oil pump drive gear [B] from the clutch housing. Lift up the crankshaft, and remove the primary chain.

Clutch Housing/Primary Chain Installation

• Install the primary chain on the sprocket of the crankshaft.

• Install the oil pump drive gear fitting its pin [A] to the groove [B] of the clutch housing sprocket.

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CRANKSHAFT/TRANSMISSION 9-15

Clutch Housing/Primary Chain

• Install the spacer [A] onto the drive shaft [B], facing the chamfered side [C] to the ball bearing [D]. Install the clutch housing in the reverse order of removal.

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Primary Chain Guide Wear Inspection

• Visually inspect the rubber on the guides.

• If the rubber is cut or damaged in any way, replace the guide.

Torque - Upper/Lower Primary Chain Guide Mounting Bolts: 11 N-m (1.1 kgf-m, 95 in-lb)

9-16 CRANKSHAFT/TRANSMISSION

Crankshaft/Connecting Rods

Crankshaft Removal

• Split the crankcase (see Crankcase Splitting).

• Remove the clutch housing and the primary chain.

• Remove the crankshaft with the camshaft chain and pri­mary chain.

CAUTION

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

Crankshaft Installation

• Apply molybdenum disulfide oil to the crankshaft bearing inserts.

• Install the camshaft and primary chains on the crankshaft.

• Align the timing mark [B] on the balancer gear [A] with the timing mark [B] on the balancer drive gear [C] of the crankshaft. Assemble the crankcase (see Crankcase Assembly).

Connecting Rod Removal

^{• Remove the crankshaft (see Crankshaft Removal).}

NOTE

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

• Remove the connecting rod big end cap nuts, and take off the rod and cap with the bearing inserts from the crank­ shaft.