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:

Tachometer
The tachometer shows the engine speed in revolutions per minute (r/min, rpm). On the right side of the tachometer face is a portion called the “red zone”. Engine r/min (rpm) in the red zone is above maximum recommended engine speed and is also above the range for good performance. ...

Immobilizer Amplifier Replacement
Remove the upper fairing assembly (see Upper Fairing Assembly Removal in the Frame chapter). Disconnect the connector [A]. Pull out the immobilizer amplifier [B] together with the rubber protector [C] from the air intake duct [D]. ECU Replacement Refer to the ECU Removal/Instal ...

Engine Removal
Support the rear part of the swingarm with a stand. Squeeze the brake lever slowly and hold it with a band [A]. WARNINGMotorcycle may fall over unexpectedly resulting in an accident or injury. Be sure to hold the front brake when removing the engine. NOTICE Be sure ...