Kawasaki Ninja Service Manual: Transmission Assy Installation

Kawasaki Ninja Service Manual / Crankshaft/Transmission / Transmission / Transmission Assy Installation

Assemble the transmission assy (see Transmission Assy Assembly).
Be sure that the dowel pins are in position.
Install the transmission assy on the crankcase.
Tighten: Torque - Transmission Case Bolts: 20 N·m (2.0 kgf·m, 15 ft·lb)
Install: Shift Shaft (see External Shift Mechanism Installation) Shift Lever (see Shift Lever Installation)
Set the gear positioning lever to the neutral position.
Check that the drive and output shaft turn freely.
Apply grease to the O-ring [A] and install it to its position on the output shaft [B].
Install the collar [C].
When installing the oil seal [D], install it as follows.

Apply grease to the oil seal lips.

Apply oil to the outer circumference of the oil seal so that it will go into place smoothly.

Install the oil seal to the crankcase so that the surface of the oil seal is flush with the surface of the crankcase.

Install the removed parts (see appropriate chapters).

Transmission Assy Installation

Transmission Shaft Removal

Refer to the Transmission Assy Disassembly.

Transmission Shaft Installation

Refer to the Transmission Assy Assembly.

Transmission Assy Assembly

Install the ball bearing [A] until it is bottomed. Turn the oil seal side to the bottom. Special Tool - Bearing Driver Set: 57001-1129 Install the bearing holder [B]. Turn the flat side ...

Transmission Shaft Disassembly

Remove the transmission shafts (see Transmission Shaft Removal). Remove the circlips, and then disassemble the transmission shafts. Special Tool - Outside Circlip Pliers: 57001-144 The 5t ...

Other materials:

Mud Guard Installation
Installation is the reverse of removal. Note the following. Run the hose and lead correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). Check the brake line. Apply a non-permanent locking agent to the threads of the mud guard mounting bolts [A, B], and tighten them ...

Current Mileage
This display mode shows the current mileage by numerical value. The current mileage display is renewed every 4 seconds. A. Current Mileage B. “km/L” NOTE The display unit modes can be changed, refer to the “Unit Setting” item in this section. The numerical value shows “ ...

DFI System Wiring Diagram
Part Names 1. Air Intake Solenoid Valve (Other than US, CA and CAL Models) 2. Front Wheel Rotation Sensor 3. Engine Stop Switch 4. Starter Button 5. Air Switching Valve 6. Stick Coil #1, #2, #3, #4 7. Spark Plugs 8. Intake Air Temperature Sensor 9. Crankshaft Sensor 10. Secondary Fuel ...