Kawasaki Ninja Service Manual: Release Shaft Installation

Kawasaki Ninja Service Manual / Clutch / Clutch Cover / Release Shaft Installation

Apply grease to the oil seal lips on the upper ridge of the clutch cover.
Apply engine oil to the needle bearings in the hole of the clutch cover.
Applymolybdenum disulfide grease to the pusher-holding portion [A] on the release shaft.
Install the washer [B] and spring [C].

Release Shaft Installation

Insert the release shaft straight into the upper hole of the clutch cover.

NOTICE

When inserting the release shaft, be careful not to remove the spring of the oil seal.

Fit the spring [A] as shown in the figure.

Release Shaft Installation

Release Shaft Removal

NOTICE Do not remove the clutch release lever and shaft assembly unless it is absolutely necessary. If removed, the oil seal replacement may be required. Remove the clutch cover (see Clutch ...

Clutch Cover Disassembly

Remove: Clutch Cover (see Clutch Cover Removal) Release Lever and Shaft Assembly (see Release Shaft Removal) Oil Seal [A] Oil Filler Plug [B] Remove: Bolts [A] Plate [B] P ...

Other materials:

Crankshaft Sensor Peak Voltage Inspection
NOTE Be sure the battery is fully charged. Using the peak voltage adapter [A] is more reliable way to determine the condition of the crankshaft sensor than crankshaft sensor internal resistance measurements. Disconnect the crankshaft sensor lead connector (see Crankshaft Sensor ...

Tightening Sequence
Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them according to the specified sequence to prevent case warpage or deformation which can lead to malfunction. Conversely when loosening the bolts, n ...

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 ...