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:

Exhaust Pipe Installation
Replace the exhaust pipe gaskets [A] and premuffler chamber gasket [B] with new ones. Install the premuffler chamber gasket to the premuffler chamber [C] until it is bottomed so that the chamfer side faces exhaust pipe [D]. Install the exhaust pipe clamp [E] as shown in the figure. I ...

Air Intake Duct Disassembly (Other than US, CA and CAL Models)
Remove: Air Intake Duct (see Air Intake Duct Removal) Seal [A] and Screen [B] Turn the air intake valve actuator [C] counterclockwise (90°). Remove the shaft [A] of the air intake valve actuator. Remove: Pad [A] Screws [B] Air Intake Valve [C] ...

CAN Communication (Transmission)/CAN Bus OFF Monitor Inspection (Service Code b 57) CAN Communication (Reception) Monitor Inspection (Service Code b 58)
Remove: Seat (see Seat Removal in the Frame chapter) Immobilizer (Equipped Models)/Kawasaki Diagnostic System Connector Cap [A] Measure the CAN communication line resistance. Immobilizer (Equipped Models)/Kawasaki Diagnostic System Connector [A] GY/BL Terminal [B] LB Ter ...