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:

Special Tools
Bearing Driver Set: 57001-1129 Jack: 57001-1238 Bearing Remover Head, 25 × 28: 57001-1346 Bearing Remover Shaft, 13: 57001-1377 Jack Attachment: 57001-1608 ...

Premuffler Chamber Installation
Replace the premuffler chamber gasket [A] with a new one. Install the premuffler chamber gasket to the premuffler chamber [B] until it is bottomed so that the chamfer side faces exhaust pipe [C]. Install the exhaust pipe clamp [D] as shown in the figure. Insert the projection [E] into ...

Radiator Inspection
Remove the radiator (see Radiator and Radiator Fan Removal). Check the radiator core. If there are obstructions to air flow, remove them. If the corrugated fins [A] are deformed, carefully straighten them. If the air passages of the radiator core are blocked more than 20% by unremovable ...