Apply liquid gasket [A] to the mating surface of the lower
Sealant - Kawasaki Bond (Liquid Gasket – gray):
Especially, apply a sealant carefully so that it shall be
filled up on the grooves.
Do not apply silicone sealant around the crankshaft
main bearing inserts, and oil passage holes.
Tighten the lower crankcase bolts, using the following
The 7 mm bolts shown [A] has a copper plated washer.
Replace it with a new one.
Apply molybdenum disulfide oil to both side of the 7 mm
bolt washers, bolt threads and seating surfaces of the
washers and bolts.
Following the sequence numbers on the lower crankcase
half, tighten the 7 mm bolts [1 ∼ 10].
Torque - Crankcase 7 mm Bolts: 24 N·m (2.4 kgf·m, 18 ft·lb)
Install the clamp [B] and tighten the 7 mm bolts [C].
Torque - Crankcase (L38 mm) 7 mm Bolts: 27 N·m (2.8
kgf·m, 20 ft·lb)
Tighten the 6 mm bolts [D].
Torque - Crankcase 6 mm Bolts: 12 N·m (1.2 kgf·m, 104
Turn the crankcase assembly up.
Tighten the upper crankcase bolts in the order listed.
Install the clamp [A].
Torque - Crankcase 7 mm Bolts [B]: 20 N·m (2.0 kgf·m, 14.5
Crankcase 6 mm Bolts [C]: 12 N·m (1.2 kgf·m, 104
After 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 9-11