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:

Crankshaft Sensor Peak Voltage Inspection
Refer to the Crankshaft Sensor Peak Voltage Inspection in the Electrical System chapter. If the reading is within the standard, remove the ECU and check the wiring for continuity between harness connectors. Special Tool - Hand Tester: 57001-1394 Disconnect the ECU and sensor connector ...

Piston Ring End Gap Inspection
Place the piston ring [A] inside the cylinder (upper crankcase), using the piston to locate the ring squarely in place. Set it close to the bottom of the cylinder, where cylinder wear is low. Measure the gap [B] between the ends of the ring with a thickness gauge. Piston Ring End Gap ...

Torque Limiter Removal
Remove: Starter Motor (see Starter Motor Removal in the Electrical System chapter) Throttle Body Assy Holder [A] Breather Hose [B] Roll up the heat insulation rubber plate [C]. Remove: Torque Limiter Cover Bolts [A] Torque Limiter Cover [B] Remove: Torque Limit ...