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:

Rear Master Cylinder Installation
Replace the washers that are on each side of hose fitting with new ones. Install the brake hose [A]. Touch the brake hose to the stopper [B] of the rear master cylinder. Tighten: Torque - Brake Hose Banjo Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb) Install the master cylinder, the brack ...

Water Temperature Sensor Removal/Installation
NOTICE Never drop the water temperature sensor especially on a hard surface. Such a shock to the sensor can damage it. Remove the throttle body assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter). Drain the coolant (see Coolant Change in the Periodic Maintenance c ...

External Shift Mechanism Inspection
Examine the shift shaft [A] for any damage. If the shaft is bent, straighten or replace it. If the serration [B] are damaged, replace the shaft. If the spring [C] is damaged in any way, replace it. If the shift mechanism arm [D] is damaged in any way, replace the shaft. Check the s ...