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9-12 CRANKSHAFT/T RANSMISSION
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]
•
Tighten the lower crankcase bolts using the following
steps.
○
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]
•
After tightening all crankcase bolts, check the following
items.
○
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.