Kawasaki Ninja Service Manual: Transmission Assy Assembly

Kawasaki Ninja Service Manual / Crankshaft/Transmission / Transmission / 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.

Transmission Assy Assembly

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)

Transmission Assy Assembly

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).

Transmission Assy Assembly

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.

Transmission Assy Assembly

Transmission Assy Disassembly

Remove the transmission assy (see Transmission Assy Removal). Remove the following from the transmission case [A]. Shift Rod [B] Shift Forks [C] Drive Shaft [D] Output Shaft [E] Shi ...

Transmission Assy Installation

Assemble the transmission assy (see Transmission Assy Assembly). Be sure that the dowel pins are in position. Install the transmission assy on the crankcase. Tighten: Torque - Transmissio ...

Other materials:

Timing Rotor Installation
Install the timing rotor [A] on the crankshaft [B] with their teeth [C] aligned. Holding the timing rotor with the flywheel & pulley holder and tighten the bolt. Torque - Timing Rotor Bolt: 39 N·m (4.0 kgf·m, 29 ft·lb) Special Tool - Flywheel & Pulley Holder: 57001-1605 I ...

Crankcase Assembly
NOTICE The upper and lower crankcase halves are machined at the factory in the assembled state, so the crankcase halves must be replaced as a set. With a high flash-point solvent, clean off the mating surfaces of the crankcase halves and wipe dry WARNINGGasoline and low flash-poin ...

Loading and accessories information
WARNINGIncorrect loading, improper installation or use of accessories, or modification of your motorcyclemay result in an unsafe riding condition. Before you ride the motorcycle, make sure it is not overloaded and that you have followed these instructions. With the ...