Crankshaft Sensor Cover Removal
The crankshaft sensor, timing rotor and lower cam chain sprocket are located behind the crankshaft sensor cover. The main reason you will need to gain access to this area is to turn the crankshaft to an exact position (see CRANKSHAFT POSITIONING-GEN1) in order to perform other procedures.
The service manual calls for thread locking agent on one of the crankshaft sensor cover bolts and the use of liquid gasket between the cover and the engine case. It is probably best to use these materials as sparingly as possible to avoid the possibility that they may detach from the surfaces they are applied to and cause internal contamination of the engine. The sealants are not materials that would damage the interior surfaces of the motor but they could easily cause blockage in the small passages that the engine oil flows through. I’ve heard that leakage from the crankshaft sensor cover will not happen even without using sealant.
Do not leave the crankcase sensor chamber open for extended periods of time to avoid contamination by dust or other foreign matter. Place the crankcase sensor cover back on the engine case if work is to be resumed at a later time.
Tools
8mm socket
rag
straight slot screw driver
drip pan
nonpermanent thread locking agent
Kawasaki 3Bond liquid gasket (part # TB1211F: 92104-0004)
Crankshaft Sensor Cover O-ring (optional)
Do First
Remove Right Lower Fairing (see Fairings Removal, Lower Fairings).
Removal
1. Remove crankshaft sensor cover bolts and the two crankshaft wire retainers with an 8mm socket. The cover will probably remain stuck in place by silicone sealant.
2. Hold the cover with one hand and use a rag covered straight slot screw driver to pry the cover from the side of the engine. 
A couple tablespoons of oil may drain out so have a drip pan ready to catch it. 
Installation
3. Remove any loose liquid gasket from the areas around the crankcase sensor cover. Wipe the mating surfaces of the engine case and crankcase sensor cover. 
4. Apply nonpermanent thread locking agent to the bolt that threads into the hole marked with a red circle. Apply a thin film of Kawasaki 3Bond liquid gasket (part # TB1211F: 92104-0004) to the engine case where indicated with blue. 
I applied a bit of engine sealant around the threaded hole (marked by the red dot). This is not called for in the service manual but it was evidently applied to this area in the factory assembly of my bike.
The top bolt hole in the engine case goes directly into the cam chain tunnel. Oil could seep through the threads. Also, the crankcase sensor grommet seems like a potential leakage point where it passes through the engine case and the crankcase sensor cover. The mark where the engine case top and bottom halves meet seems as though it could allow some seepage past the gasket on the sensor cover.
5. Remove the old O-ring and clean out the channel in the cover. Replace the O-ring in the cover with a new one.
I applied the liquid gasket sparingly to the cover instead of the engine case. I tried to apply the sealant to the outside of the O-ring gasket to prevent the sealant from getting squeezed out on the inside of the motor.
I have removed the crankshaft sensor cover three times without replacing the O-ring so I would consider its replacement as being optional.
6. Place the cover onto the engine case with the two wire retainers on top of the cover and lined up with the proper bolt hole. Torque the bolts with a torque wrench and an 8mm socket.
Torque Spec for Crankcase Sensor Cover bolts is 87 in lbs.
Install Right Lower Fairing (see Fairings Removal, Lower Fairings).
* Last updated by: Rook on 1/6/2018 @ 1:09 PM *