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:

Upper Fairing Assembly Removal
Remove: Lower Fairings (see Lower Fairing Removal) Center Inner Fairing (see Center Inner Fairing Removal) Upper Inner Fairings (see Upper Inner Fairing Removal) Windshield (see Windshield Removal) Disconnect the front turn signal light lead connector [A] (both sides). Remove the bo ...

Meter instruments
Upper Button Lower Button Tachometer (with Shift-Up Indicator) Red Zone Ambient Brightness Sensor Turn Signal Indicator Light Warning Indicator Light (Red) Neutral Indicator Light Multifunction Meter High Beam Indicator Light Warning Indicator Light (Yellow) Fuel ...

Piston Installation
Apply molybdenum disulfide oil solution to the oil ring expander, and install the oil ring expander [A] in the bottom piston ring groove so the ends [B] not butt together Applymolybdenum disulfide oil solution to the oil ring steel rails, and install the oil ring steel rails, one above th ...