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:

Storage
Preparation for Storage Clean the entire vehicle thoroughly Run the engine for about five minutes to warm the oil, shut it off, and drain the engine oil. WARNINGEngine oil is a toxic substance. Dispose of used oil properly. Contact your local authorities for approved disp ...

ABS and KIBS Indicator Lights (LED) Inspection
In this model, the ABS indicator light (LED) [A] and KIBS indicator light (LED) [B] go on or blink by the data sent from the KIBS hydraulic unit. Refer to the Meter Unit Inspection in the Electrical System chapter. ABS and KIBS Indicator Lights (LED) Function *: The mode of “Low ...

Periodic Maintenance Chart
The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. The initial maintenance is vitally important and must not be neglected. Periodic Inspection #: Service more frequently when operating in severe conditions; dusty, ...