Kawasaki Ninja Service Manual: Starter Clutch Installation

Kawasaki Ninja Service Manual / Crankshaft/Transmission / Starter Clutch / Starter Clutch Installation

Replace the O-ring [A] with a new one and apply grease.
Apply molybdenum disulfide grease to the starter clutch shaft [B].
Install: Starter Clutch [C] Spacer (Small Diameter) [D] Spacer (Large Diameter) [E] Starter Clutch Shaft Starter Clutch Shaft Holder [F]

Turn the O-ring side of the shaft to outside as shown in the figure.

Apply a non-permanent locking agent to the starter clutch shaft bolt [G] and the starter clutch shaft holder bolt [H].
Tighten: Torque - Starter Clutch Shaft Holder Bolt: 9.8 N·m (1.0 kgf·m, 87 in·lb) Starter Clutch Shaft Bolt: 20 N·m (2.0 kgf·m, 15 ft·lb)

Starter Clutch Installation

Install the removed parts (see appropriate chapters).

Starter Clutch Removal

Remove: Torque Limiter (see Torque Limiter Removal) Transmission Assy (see Transmission Assy Removal) Starter Clutch Shaft Holder Bolt [A] Starter Clutch Shaft Bolt [B] Starter Clutch Sha ...

Starter Clutch Disassembly

Remove the starter clutch (see Starter Clutch Removal). Take the drive gear [A] off the driven gear [B]. Remove the needle bearing [C]. Remove the snap ring [D]. Take the one-way clutch [E] ...

Other materials:

Stick Coil Installation
Apply a thin coat of grease [A] to the stick coils for easy installation. Insert the stick coils so that the coil heads align with the lines [B] on the cylinder head cover. NOTICE Do not tap the coil head while installing the coil. After installation, be sure the stick coils are ...

For Primary Fuel Injectors
Remove the air cleaner housing (see Air Cleaner Housing Removal). Disconnect the primary fuel injector connector [A]. Connect a digital meter to the terminals in each primary fuel injector [A]. Measure the primary fuel injector resistance. Primary Fuel Injector Resistance ...

Oil Level Inspection
If the oil has just been changed, start the engine and run it for severalminutes at idle speed. This fills the oil filter with oil. Stop the engine, then wait several minutes until the oil settles. NOTICE Racing the engine before the oil reaches every part can cause engine seizure. ...