Kawasaki Ninja Service Manual: Transmission Shaft Assembly

Kawasaki Ninja Service Manual / Crankshaft/Transmission / Transmission / Transmission Shaft Assembly

Apply molybdenum disulfide oil solution to the sliding surfaces of the gears and shafts.
Install the gears and the gear bushings [A] with their holes [B] aligned.

Transmission Shaft Assembly

Replace any circlips removed with new ones.
Install the circlips [A] so that the opening [B] of it is aligned with spline grooves [C].
Install the circlips so that the mark [D] on them faces to each gear side.

Transmission Shaft Assembly

The drive shaft gears can be recognized by size: the gear with the smallest diameter is 1st gear, and the largest one is 6th gear. Be sure that all parts are put back in the correct sequence and all circlips and washers are properly in place.
Install the 3rd/4th gear onto the drive shaft with their oil holes aligned.
Install the 5th and 6th gear bushings onto the drive shaft with their oil holes aligned.
The output shaft gears can be recognized by size: the gear with the largest diameter is 1st gear, and the smallest one is 6th gear. Be sure that all parts are put back in the correct sequence and all circlips and washers are properly in place.
Install the 6th gear onto the output shaft with their oil holes aligned.
Install the 1st, 2nd and 3rd/4th gear bushings onto the output shaft with their oil holes aligned.

Fit the steel balls into the 5th gear holes in the output shaft.

5th Gear [A] Output Shaft [B] Steel Balls [C]

Transmission Shaft Assembly

NOTICE

Do not apply grease to the balls to hold them in place. This will cause the positive neutral finder mechanism to malfunction.

After assembling the 5th gear with steel balls in place on the output shaft, check the ball-locking effect that the 5th gear does not come out of the output shaft when moving it up and down by hand.

Check that each gear spins or slides freely on the transmission shafts without binding after assembly.

Transmission

1. 1st Gear

2. 2nd Gear

3. 3rd Gear

4. 4th Gear

5. 5th Gear

6. 6th (Top) Gear

7. Drive Shaft

8. Output Shaft

9. Circlip (Turn the punch mark to the gear.)

10. Toothed Washer

11. Toothed Washer

12. Toothed Bushing, L = 15 mm (0.60 in.)

13. Toothed Washer

14. Circlip (Turn the punch mark to the washer.)

15. Bushing, 31 mm (1.2 in.)

16. Toothed Bushing, L = 9.4 mm (0.37 in.)

17. Washer

18. Bushing, 25 mm (1.0 in.)

Shift Drum and Fork Removal

Refer to the Transmission Assy Disassembly.

Shift Drum and Fork Installation

Refer to the Transmission Assy Assembly.

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 ...

Shift Drum Disassembly

Remove the shift drum (see Transmission Assy Disassembly). While holding the shift drum with a vise, remove the shift drum cam holder bolt [A]. Remove: Shift Drum Cam [B] Dowel Pin [C] ...

Other materials:

Starter Motor Disassembly
Remove the starter motor (see Starter Motor Removal). Take off the starter motor through bolts [A] and remove the both end covers [B]. Pull out the armature [A] out of the yoke [B]. NOTE Do not remove the circlip [C] from the shaft. Remove the starter motor terminal lock ...

Electrical Wiring
Wiring Inspection Visually inspect the wiring for signs of burning, fraying, etc. If any wiring is poor, replace the damaged wiring. Pull each connector [A] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clean it carefully. If it is da ...

Exhaust System Identification
Exhaust Pipe Mark Position [A] Premuffler Chamber Mark Position [A] Muffler Body Mark Position [A] Premuffler Chamber [A] with Hole [B] for Oxygen Sensor [C] Honeycomb Type Catalyst Position [A] Specifications ...