Kawasaki Ninja Service Manual: Transmission Shaft Assembly

Kawasaki Ninja Service Manual / Crankshaft/Transmission / Transmission / Transmission Shaft Assembly

Transmission Shaft Assembly


Transmission Shaft Assembly


Fit the steel balls into the 5th gear holes in the output shaft.

5th Gear [A] Output Shaft [B] Steel Balls [C]

Transmission Shaft Assembly


NOTICE

Do not apply grease to the balls to hold them in place. This will cause the positive neutral finder mechanism to malfunction.

After assembling the 5th gear with steel balls in place on the output shaft, check the ball-locking effect that the 5th gear does not come out of the output shaft when moving it up and down by hand.

Transmission


1. 1st Gear

2. 2nd Gear

3. 3rd Gear

4. 4th Gear

5. 5th Gear

6. 6th (Top) Gear

7. Drive Shaft

8. Output Shaft

9. Circlip (Turn the punch mark to the gear.)

10. Toothed Washer

11. Toothed Washer

12. Toothed Bushing, L = 15 mm (0.60 in.)

13. Toothed Washer

14. Circlip (Turn the punch mark to the washer.)

15. Bushing, 31 mm (1.2 in.)


16. Toothed Bushing, L = 9.4 mm (0.37 in.)

17. Washer

18. Bushing, 25 mm (1.0 in.)


Shift Drum and Fork Removal

Refer to the Transmission Assy Disassembly.

Shift Drum and Fork Installation

Refer to the Transmission Assy Assembly.

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 ...

Shift Drum Disassembly
Remove the shift drum (see Transmission Assy Disassembly). While holding the shift drum with a vise, remove the shift drum cam holder bolt [A]. Remove: Shift Drum Cam [B] Dowel Pin [C] ...

Other materials:

Kawasaki Intelligent anti-lock Brake System (KIBS, For models equipped with KIBS)
KIBS regulates anti-lock braking performance with more precision during sports riding compared to a conventional ABS system. KIBS is designed to help prevent the wheels from locking up when the brakes are applied hard while riding straight. KIBS automatically regulates brake force using en ...

Connecting Rod Bend Inspection
Remove the connecting rod big end bearing inserts, and reinstall the connecting rod big end cap. Select an arbor [A] of the same diameter as the connecting rod big end, and insert the arbor through the connecting rod big end. Select an arbor of the same diameter as the piston pin and ...

Front Wheel Installation
NOTE The direction of the wheel rotation [A] is shown by an arrow [B] on the wheel spoke. Check the wheel rotation mark on the front wheel and install it. Apply high-temperature grease to the grease seal lips. Fit the collars [A] on the both sides of the hub. The collars are i ...