Kawasaki Ninja Service Manual: 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 to the bottom.

• Apply a non-permanent locking agent to the bearing holder bolts [C].
• Tighten: Torque - Transmission Case Bearing Holder Bolts: 4.9 N·m (0.50 kgf·m, 43 in·lb)
• Install the dowel pins [D] until they are bottomed.

• Install the ball bearing [A] until it is bottomed.

Turn the stepped edge to upside.

Special Tool - Bearing Driver Set: 57001-1129

• Install the bearing holder [B].

Turn the flat side to the bottom.

• Apply a non-permanent locking agent to the bearing holder bolts [C].

Tighten: Torque - Transmission Case Bearing Holder Bolts: 4.9 N·m (0.50 kgf·m, 43 in·lb)

• Install the ball bearing [D] until it is bottomed.
• Install the bearing holders [E].

Turn the flat side to the bottom.

• Apply a non-permanent locking agent to the bearing holder bolts [F].
• Tighten: Torque - Transmission Case Bearing Holder Bolts: 4.9 N·m (0.50 kgf·m, 43 in·lb)
• Install the pin [G] until it is bottomed.
• Apply a non-permanent locking agent to the shift shaft return spring pin [H].
• Tighten: Torque - Shift Shaft Return Spring Pin: 29 N·m (3.0 kgf·m, 21 ft·lb)

• Install the following parts as shown in the figure.

  Spring [A] Washer [B] Gear Positioning Lever [C]

• Tighten: Torque - Gear Positioning Lever Bolt [D]: 12 N·m (1.2 kgf·m, 106 in·lb)
• Install the shift ratchet assembly (see External ShiftMechanism Installation).

• Install the drive shaft [A] and output shaft [B] as a set in the transmission case [C]
• Install the shift forks as shown in the figure.

The shift fork [D] for drive shaft has “A2” mark. Turn the mark to the upside.

The shift forks [E] for output shaft have “A1” mark. Turn the mark to the bottom.

The shift forks [F] for output shaft have “A3” mark. Turn the mark to the bottom.

• Install the shift rod [G].
• Apply molybdenum disulfide oil solution to the transmission gears (x marks) [H].
• Install the washer [I] on the output shaft.