Kawasaki Ninja Service Manual: Transmission Assy Installation

Kawasaki Ninja Service Manual / Crankshaft/Transmission / Transmission / 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 - Transmission Case Bolts: 20 N·m (2.0 kgf·m, 15 ft·lb)
Install: Shift Shaft (see External Shift Mechanism Installation) Shift Lever (see Shift Lever Installation)
Set the gear positioning lever to the neutral position.
Check that the drive and output shaft turn freely.
Apply grease to the O-ring [A] and install it to its position on the output shaft [B].
Install the collar [C].
When installing the oil seal [D], install it as follows.

Apply grease to the oil seal lips.

Apply oil to the outer circumference of the oil seal so that it will go into place smoothly.

Install the oil seal to the crankcase so that the surface of the oil seal is flush with the surface of the crankcase.

Install the removed parts (see appropriate chapters).

Transmission Assy Installation

Transmission Shaft Removal

Refer to the Transmission Assy Disassembly.

Transmission Shaft Installation

Refer to the Transmission Assy Assembly.

Transmission Assy Assembly

Install the ball bearing [A] until it is bottomed. Turn the oil seal side to the bottom. Special Tool - Bearing Driver Set: 57001-1129 Install the bearing holder [B]. Turn the flat side ...

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 ...

Other materials:

Coolant Level Inspection
NOTE Check the level when the engine is cold (room or ambient temperature). Check the coolant level in the reserve tank [A] with the motorcycle held perpendicular (Do not use the sidestand). If the coolant level is lower than the “L” level line [B], remove the upper fairing assembly (s ...

Coolant Reserve Tank Installation
Install the following to the coolant reserve tank [A]. Pad [B] Gasket [C] Cap [D] Collar [E] Install the coolant reserve tank and tighten the bolt [F]. Run the hoses correctly (see Cable,Wire, and Hose Routing section in the Appendix chapter). Fill the coolant reserve tank with ...

Stick Coil Inspection
Remove the stick coils (see Stick Coil Removal). Measure the primary winding resistance [A] as follows. Connect the hand tester between the coil terminals. Set the tester to the × 1 Ω range, and read the tester. Measure the secondary winding resistance [B] as follows. Conn ...