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 to-
gether as a set.
Using compressed air, blow out the oil passages [A] in the
With a high-flash point solvent, clean off the mating sur-
faces of the crankcase halves and wipe dry.
Before fitting the lower case on the upper case, check the
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 to the mating surface of the lower
Sealant - Kawasaki Bond (Liquid Gasket - Silver): 92104
Do not apply liquid gasket around the crankshaft
main bearing inserts and balancer shaft inserts.
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 [B] of the gears.