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:

Engine Sprocket Removal
Remove: Engine Sprocket Cover Bolts [A] Engine Sprocket Cover [B] Flatten out the bended washer [A]. Remove the engine sprocket nut [B] and washer. NOTE When loosening the engine sprocket nut, hold the rear brake on. Raise the rear wheel off the ground with the stand. ...

Oil Cooler Installation
Replace the O-ring [A] with a new one. Apply grease to the new O-ring. Install the water hoses and hose clamps [A] as shown in the figure. Water Hose (About 300 mm, 11.8 in.) [B] Water Hose (About 130 mm, 5.1 in.) [C] Yellow Paint [D] Tighten: Torque - Water Hose Clamp S ...

Exhaust Butterfly Valve Actuator Resistance Inspection
Turn the ignition switch to OFF. Disconnect the exhaust butterfly valve actuator lead connector (2 pins connector) [A]. Set the hand tester to the × 1 Ω range and connect it to the exhaust butterfly valve actuator connector. Special Tool - Hand Tester: 57001-1394 Measure ...