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:

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 circlips removed with new ones. Install the circlips [A] so that the opening [B] of it is aligned with ...

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 ...

Nozzle Assy Assembly
Before assembling, blow away dirt or dust from the delivery pipes [A] by applying compressed air [B]. Replace the O-rings [A] of the joint pipe [B] with new ones. Apply engine oil to the new O-rings, and insert it to the delivery pipes [C] Insert the joint pipe so that the step ...