Kawasaki Ninja Service Manual: Transmission Shaft Disassembly

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

Special Tool - Outside Circlip Pliers: 57001-144

The 5th gear [A] on the output shaft has three steel balls assembled into it for the positive neutral finder mechanism.

Remove the 5th gear as follows.

Transmission Shaft Disassembly


Set the output shaft in a vertical position holding the 3rd gear [B].

Spin the 5th gear quickly [C] and pull it off upward.

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 ...

Transmission Shaft Assembly
Apply molybdenum disulfide oil solution to the sliding surfaces of the gears and shafts. Install the gears and the gear bushings [A] with their holes [B] aligned. Replace any circli ...

Other materials:

Shift Pedal Removal
Remove: Shift Lever Bolt [A] Front Footpeg Bracket Bolts [B] If the tie-rod [C] is to be removed from the shift pedal and the shift lever, loosen the tie-rod locknuts [D]. The front tie-rod locknut is left-hand thread. Remove: Shift Pedal Mounting Bolt [A] ...

Front Wheel Rotation Sensor Signal (Service Code 27)
Front Wheel Rotation Sensor Signal Inspection The front wheel rotation sensor sends the signal to the ECU through the KIBS hydraulic unit (KIBS equipped models). For other than KIBS equipped models, the signal is sent directly to the ECU. The ECU uses the wheel rotation sensor signal for KTRC ...

Headlight Beam
NOTE Do not turn the bolts because the reflector in the headlight comes off. A. Bolts The left and right adjusters on the headlight can move the direction of the headlight beam to up, down, left and right by turning each adjuster itself as the below table. A. Left Adjuster ...