Kawasaki Ninja Service Manual: Transmission Shaft Assembly

Kawasaki Ninja Service Manual / Crankshaft/Transmission / Transmission / Transmission Shaft Assembly

Transmission Shaft Assembly


Transmission Shaft Assembly


Fit the steel balls into the 5th gear holes in the output shaft.

5th Gear [A] Output Shaft [B] Steel Balls [C]

Transmission Shaft Assembly


NOTICE

Do not apply grease to the balls to hold them in place. This will cause the positive neutral finder mechanism to malfunction.

After assembling the 5th gear with steel balls in place on the output shaft, check the ball-locking effect that the 5th gear does not come out of the output shaft when moving it up and down by hand.

Transmission


1. 1st Gear

2. 2nd Gear

3. 3rd Gear

4. 4th Gear

5. 5th Gear

6. 6th (Top) Gear

7. Drive Shaft

8. Output Shaft

9. Circlip (Turn the punch mark to the gear.)

10. Toothed Washer

11. Toothed Washer

12. Toothed Bushing, L = 15 mm (0.60 in.)

13. Toothed Washer

14. Circlip (Turn the punch mark to the washer.)

15. Bushing, 31 mm (1.2 in.)


16. Toothed Bushing, L = 9.4 mm (0.37 in.)

17. Washer

18. Bushing, 25 mm (1.0 in.)


Shift Drum and Fork Removal

Refer to the Transmission Assy Disassembly.

Shift Drum and Fork Installation

Refer to the Transmission Assy Assembly.

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 ...

Shift Drum Disassembly
Remove the shift drum (see Transmission Assy Disassembly). While holding the shift drum with a vise, remove the shift drum cam holder bolt [A]. Remove: Shift Drum Cam [B] Dowel Pin [C] ...

Other materials:

Rider’s Seat Installation
Insert the tabs on the front of the rider’s seat into the slots in the frame and secure the seat with mounting bolts. Install the seat cover and bolts. A. Rider’s Seat B. Tabs C. Slots D. Stays ...

Clutch Cover Installation
Using a cleaning fluid, clean off any oil or dirt that may be on the silicone sealant coating area. Dry them with a clean cloth. Apply silicone sealant to the area [A] where the mating surface of the crankcase touches the clutch cover gasket. Sealant - Liquid Gasket, TB1211F: 92104-000 ...

Air Cleaner
A clogged air cleaner restricts the engine’s air intake, increasing fuel consumption, reducing engine power, and causing spark plug fouling. This motorcycle’s air cleaner element consists of a wet paper filter, which cannot be cleaned. The air cleaner element must be replaced in acco ...