Kawasaki Ninja Service Manual: Transmission Assy Installation

Kawasaki Ninja Service Manual / Crankshaft/Transmission / Transmission / 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 - Transmission Case Bolts: 20 N·m (2.0 kgf·m, 15 ft·lb)
Install: Shift Shaft (see External Shift Mechanism Installation) Shift Lever (see Shift Lever Installation)
Set the gear positioning lever to the neutral position.
Check that the drive and output shaft turn freely.
Apply grease to the O-ring [A] and install it to its position on the output shaft [B].
Install the collar [C].
When installing the oil seal [D], install it as follows.

Apply grease to the oil seal lips.

Apply oil to the outer circumference of the oil seal so that it will go into place smoothly.

Install the oil seal to the crankcase so that the surface of the oil seal is flush with the surface of the crankcase.

Install the removed parts (see appropriate chapters).

Transmission Assy Installation

Transmission Shaft Removal

Refer to the Transmission Assy Disassembly.

Transmission Shaft Installation

Refer to the Transmission Assy Assembly.

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 ...

Transmission Shaft Disassembly

Remove the transmission shafts (see Transmission Shaft Removal). Remove the circlips, and then disassemble the transmission shafts. Special Tool - Outside Circlip Pliers: 57001-144 The 5t ...

Other materials:

Crankshaft Side Clearance Inspection
Insert a thickness gauge [A] between the thrust washer [B] on the crankcase and the crank web [C] at the #3 main journal to determine clearance. If the clearance exceeds the service limit, replace the thrust washers as a set and check the width of the crankshaft #3 main journal. Cra ...

City Light (LED) Removal/Installation
Remove: Upper Fairing Assembly (see Upper Faring Assembly Removal in the Frame chapter) Headlight (see Headlight Removal) Remove the screws [A], and take the city light [B] off the upper fairing assembly. Installation is the reverse of removal. Note the following. When inst ...

Connecting Rod Big End Bearing Insert/Crankpin Wear Inspection
Remove the connecting rod big end (see Connecting Rod Removal). Cut strips of plastigage to crankpin width. Place a strip on the crankpin parallel to the crankshaft installed in the correct position. Tighten the connecting rod big end nuts to the specified torque (see Connecting Rod I ...