Kawasaki Ninja Service Manual: Transmission Shaft Disassembly

Kawasaki Ninja Service Manual / Crankshaft/Transmission / Transmission / 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 5th gear [A] on the output shaft has three steel balls assembled into it for the positive neutral finder mechanism.

Remove the 5th gear as follows.

Transmission Shaft Disassembly

Set the output shaft in a vertical position holding the 3rd gear [B].

Spin the 5th gear quickly [C] and pull it off upward.

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 - Transmissio ...

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. Replace any circli ...

Other materials:

Oxygen Sensor - not activated (Service Code 33, Equipped Models)
Oxygen Sensor Removal/Installation Refer to the Oxygen Sensor Removal/Installation (Equipped Models) in the Electrical System chapter. Oxygen Sensor Inspection Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Oxygen Sensor Lead Connector [A] Connect t ...

Connecting Rod Installation
NOTICE To minimize vibration, the connecting rods should have the same weight mark. Big End Cap [A] Connecting Rod [B] Weight Mark, Alphabet [C] Diameter Mark [D] (“” or No Mark) NOTICE If the connecting rods, big end bearing inserts, or crankshaft are replaced with new ones, select ...

Battery Charging
Remove the battery from the motorcycle (see Battery Removal). Attach the leads from the charger and charge the battery at a rate (amperage x hours) that is indicated on the battery. If it is not possible to read the rate, charge the battery at an amperage that is about 1/10th of the ...