Kawasaki Ninja 300 / Ninja 300 ABS Motorcycle. Service Manual (2013)

8-6 ENGINE REMOVAL/INSTALLATION

Engine Removal/Installation

•

Insert the rear lower engine mounting bolt [A] first from
left side while supporting the engine. Then insert the rear
upper engine mounting bolt [B] from left side, and tighten
the nuts temporarily.

•

Install the following temporarily:

Front Middle Engine Mounting Bolt [A]
Side Dampers [B]
Front Middle Engine Mounting Nut [C]

•

Install the front upper engine mounting bracket [A] (Both
Sides) and tighten the nuts [B] temporarily.

•

Install the front lower engine mounting bracket [C] and
tighten the nut [D] temporarily.

•

By the following specified sequence, tighten the bolts.

Torque - Rear Engine Mounting Nuts [A]: 69 N·m (7.0 kgf·m,

51 ft·lb)

Front Upper Engine Mounting Bolts [B]: 69 N·m

(7.0 kgf·m, 51 ft·lb)

Front Lower Engine Mounting Nut [C]: 69 N·m (7.0

kgf·m, 51 ft·lb)

Front Middle Engine Mounting Nut [D]: 44 N·m (4.5

kgf·m, 32 ft·lb)

•

Run the leads, cables and hoses correctly (see Cable,
Wire, and Hose Routing section in the Appendix chapter).

•

Install the removed parts (see appropriate chapters).

•

Adjust:

Throttle Cables (see Throttle Control System Inspection
in the Periodic Maintenance chapter)
Clutch Cable (see Clutch Operation Inspection in the Pe-
riodic Maintenance chapter)
Drive Chain (see Drive Chain Slack Inspection in the
Periodic Maintenance chapter)

•

Fill the engine with engine oil (see Engine Oil Change in
the Periodic Maintenance chapter).

•

Fill the engine with coolant (see Coolant Change in the
Periodic Maintenance chapter).

CRANKSHAFT/TRANSMISSION 9-1

Crankshaft/Transmission

Table of Contents

Exploded View...................................

9-2

Specifications ....................................

9-6

Special Tools and Sealant .................

9-9

Crankcase ........................................

9-10

Crankcase Splitting ......................

9-10

Crankcase Assembly ...................

9-11

Crankshaft and Connecting Rods......

9-14

Crankshaft Removal ....................

9-14

Crankshaft Installation .................

9-14

Connecting Rod Removal ............

9-14

Connecting Rod Installation .........

9-15

Crankshaft/Connecting Rod

Cleaning ....................................

9-18

Connecting Rod Bend Inspection

9-19

Connecting Rod Twist Inspection.

9-19

Connecting Rod Big End Side

Clearance Inspection ................

9-19

Connecting Rod Big End

Bearing Insert/Crankpin Wear
Inspection..................................

9-20

Crankshaft Side Clearance

Inspection..................................

9-21

Crankshaft Runout Inspection......

9-22

Crankshaft Main Bearing

Insert/Journal Wear Inspection .

9-22

Starter Motor Clutch ..........................

9-24

Starter Motor Clutch

Removal/Installation..................

9-24

Starter Motor Clutch Inspection ...

9-24

Starter Motor Clutch Disassembly

9-24

Starter Motor Clutch Assembly ....

9-24

Balancer ............................................

9-25

Balancer Removal........................

9-25

Balancer Installation.....................

9-25

Balancer Shaft Bearing

Insert/Journal Wear Inspection .

9-25

Transmission .....................................

9-27

Shift Pedal Removal ....................

9-27

Shift Pedal Installation .................

9-27

External Shift Mechanism

Removal ....................................

9-28

External Shift Mechanism

Installation .................................

9-28

External Shift Mechanism

Inspection..................................

9-28

Transmission Shaft Removal .......

9-29

Transmission Shaft Installation ....

9-29

Transmission Shaft Disassembly.

9-30

Transmission Shaft Assembly......

9-31

Shift Drum and Fork Removal......

9-33

Shift Drum and Fork Installation...

9-33

Shift Drum Disassembly...............

9-34

Shift Drum Assembly ...................

9-34

Shift Fork Bending Inspection ......

9-34

Shift Fork/Gear Groove Wear

Inspection..................................

9-35

Shift Fork Guide Pin/Drum

Groove Wear Inspection ...........

9-35

Gear Dog and Gear Dog Hole

Damage Inspection ...................

9-35

CRANKSHAFT/TRANSMISSION 9-3

Exploded View

Torque

No.

Fastener

N·m

kgf·m

ft·lb

Remarks

Connecting Rod Big End Nuts

see the text

←

MO, R

Shift Drum Bearing Holder Screws

4.4

0.45

39 in·lb

Oil Breather Mounting Bolts

9.8

1.0

87 in·lb

Starter Motor Clutch Bolts

34.3

3.50

25.3

Crankcase Bolts (M8, L = 73 mm)

23.5

2.40

17.3

MO, S

Crankcase Bolts (M6, L = 38, 60, 85 mm)

1.1

97 in·lb

Crankcase Bolt (M6, L = 135 mm)

1.1

97 in·lb

Crankcase Bolts (M8, L = 90 mm)

27.5

2.80

20.3

MO, S

G: Apply grease.

L: Apply a non-permanent locking agent.

LG: Apply liquid gasket (ThreeBond TB1216B).

M: Apply molybdenum disulfide grease.

MO: Apply molybdenum disulfide oil solution.

(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1)

R: Replacement Parts

S: Follow the specified tightening sequence.

CRANKSHAFT/TRANSMISSION 9-5

Exploded View

Torque

No.

Fastener

N·m

kgf·m

ft·lb

Remarks

1 Gear Positioning Lever Bolt

1.2

106 in·lb

2 Shift Lever Bolt

1.2

106 in·lb

3 Shift Shaft Return Spring Pin

19.6

2.0

14.5

4 Shift Drum Cam Bolt

9.0

0.92

80 in·lb

5 Tie-Rod Locknut (Front)

9.8

1.0

87 in·lb

6 Tie-Rod Locknut (Rear)

9.8

1.0

87 in·lb

7 Neutral Switch

1.5

8 Shift Pedal Mounting Bolt

1.2

106 in·lb

EO: Apply engine oil.

G: Apply grease.

L: Apply a non-permanent locking agent.

Lh: Left-hand Threads

R: Replacement Parts

9-6 CRANKSHAFT/TRANSMISSION

Specifications

Item

Standard

Service Limit

Crankshaft, Connecting Rods

Connecting Rod Bend

– – –

TIR 0.2/100 mm

(0.008/3.94 in.)

Connecting Rod Twist

– – –

TIR 0.2/100 mm

(0.008/3.94 in.)

Connecting Rod Big End Side Clearance

0.13

∼

0.38 mm

(0.0051

∼

0.0150 in.)

0.58 mm

(0.023 in.)

Connecting Rod Big End Bearing
Insert/Crankpin Clearance

0.032

∼

0.066 mm

(0.0013

∼

0.0026 in.)

0.10 mm

(0.0039 in.)

Crankpin Diameter:

29.984

∼

30.000 mm

(1.1805

∼

1.1811 in.)

29.97 mm

(1.1799 in.)

Marking

None

29.984

∼

29.994 mm

(1.1805

∼

1.1809 in.)

– – –

○

29.995

∼

30.000 mm

(1.1809

∼

1.1811 in.)

– – –

Connecting Rod Big End Inside Diameter: 33.000

∼

33.016 mm

(1.2992

∼

1.2998 in.)

– – –

Marking

None

33.000

∼

33.008 mm

(1.2992

∼

1.2995 in.)

– – –

○

33.009

∼

33.016 mm

(1.2996

∼

1.2998 in.)

– – –

Connecting Rod Big End Bearing Insert
Thickness:

Brown

1.480

∼

1.485 mm

(0.05827

∼

0.05846 in.)

– – –

Black

1.485

∼

1.490 mm

(0.05846

∼

0.05866 in.)

– – –

Blue

1.489

∼

1.494 mm

(0.05862

∼

0.05882 in.)

– – –

Crankshaft Side Clearance

0.05

∼

0.20 mm

(0.0020

∼

0.0079 in.)

0.40 mm

(0.0157 in.)

Crankshaft Runout

TIR 0.02 mm (0.0008 in.) or
less

TIR 0.05 mm

(0.0020 in.)

Crankshaft Main Bearing Insert/Journal
Clearance

0.016

∼

0.048 mm

(0.0006

∼

0.0019 in.)

0.08 mm

(0.0031 in.)

Crankshaft Main Journal Diameter:

27.984

∼

28.000 mm

(1.1017

∼

1.1024 in.)

27.96 mm

(1.101 in.)

Marking

None

27.984

∼

27.992 mm

(1.1017

∼

1.1020 in.)

– – –

27.993

∼

28.000 mm

(1.1021

∼

1.1024 in.)

– – –

Crankcase Main Bearing Inside Diameter: 31.000

∼

31.016 mm

(1.2205

∼

1.2211 in.)

– – –

CRANKSHAFT/TRANSMISSION 9-7

Specifications

Item

Standard

Service Limit

Marking

○

31.000

∼

31.008 mm

(1.2205

∼

1.2208 in.)

– – –

None

31.009

∼

31.016 mm

(1.2208

∼

1.2211 in.)

– – –

Crankshaft Main Bearing Insert Thickness:

Black

1.495

∼

1.499 mm

(0.05885

∼

0.05902 in.)

– – –

Blue

1.499

∼

1.503 mm

(0.05902

∼

0.05917 in.)

– – –

Yellow

1.503

∼

1.507 mm

(0.05917

∼

0.05933 in.)

– – –

Balancer

Balancer Shaft Bearing Insert/Journal
Clearance

0.014

∼

0.050 mm

(0.0006

∼

0.0020 in.)

0.08 mm

(0.0031 in.)

Balancer Shaft Journal Diameter:

25.984

∼

26.000 mm

(1.0230

∼

1.0236 in.)

25.96 mm

(1.022 in.)

Marking

None

25.984

∼

25.994 mm

(1.0230

∼

1.0234 in.)

– – –

○

25.995

∼

26.000 mm

(1.0234

∼

1.0236 in.)

– – –

Balancer Shaft Bearing Inside Diameter:

29.000

∼

29.016 mm

(1.1417

∼

1.1424 in.)

– – –

Marking

○

29.000

∼

29.008 mm

(1.1417

∼

1.1420 in.)

– – –

None

29.009

∼

29.016 mm

(1.1421

∼

1.1424 in.)

– – –

Balancer Shaft Bearing Insert Thickness:

Brown

1.495

∼

1.499 mm

(0.05885

∼

0.05902 in.)

– – –

Black

1.499

∼

1.503 mm

(0.05902

∼

0.05917 in.)

– – –

Blue

1.503

∼

1.507 mm

(0.05917

∼

0.05933 in.)

– – –

Transmission

Shift Fork Ear Thickness

4.9

∼

5.0 mm

(0.193

∼

0.197 in.)

4.8 mm

(0.189 in.)

Gear Groove Width

5.05

∼

5.15 mm

(0.199

∼

0.203 in.)

5.3 mm

(0.209 in.)

Shift Fork Guide Pin Diameter

5.9

∼

6.0 mm

(0.232

∼

0.236 in.)

5.8 mm

(0.228 in.)

Shift Drum Groove Width

6.05

∼

6.20 mm

(0.238

∼

0.244 in.)

6.3 mm

(0.248 in.)

9-8 CRANKSHAFT/TRANSMISSION

Specifications

Connecting Rod Big End Bearing Insert Selection

Bearing Insert

Con-rod Big End

Inside Diameter

Marking

Crankpin Diameter

Marking

Size Color

Part Number

None

○

Brown

92139-0784

None

○

Black

92139-0783

○

None

Blue

92139-0782

Crankshaft Main Bearing Insert Selection

Bearing Insert*

Crankcase Main

Bearing Inside

Diameter Marking

Crankshaft Main

Journal Diameter

Marking

Size Color

Part Number

Journal Nos.

92139-0787

1, 3

○

Black

92139-0791

None

92139-0786

1, 3

○

None

Blue

92139-0790

92139-0788

1, 3

None

Yellow

92139-0792

*: The bearing insert for Nos. 2 journal have an oil groove.

Balancer Shaft Bearing Insert Selection

Bearing Insert

Balancer Shaft

Journal Diameter

Marking

Balancer Shaft

Bearing Inside

Diameter Marking

Size Color

Part Number

○

Brown

92028-1424

○

None

○

Black

92028-1423

None

Blue

92028-1422

CRANKSHAFT/TRANSMISSION 9-11

Crankcase

•

Remove:

Oil Pan (see Oil Pan Removal in the Engine Lubrication
System chapter)
Oil Screen (see Oil Pan Removal in the Engine Lubrica-
tion System chapter)
Oil Pressure Relief Valve (see Oil Pressure Relief Valve
Removal in the Engine Lubrication System chapter)

•

Remove the lower crankcase bolts.

○

First, loosen the M6 bolts [A].

○

Lastly, loosen the M8 bolts [B].

•

Tap lightly around the crankcase mating surface with a
plastic mallet, and split the crankcase.

○

Take care not to damage the crankcase.

If the breather plate [A] is to be removed, follow the next
procedure.

○

Cut the gasket around the plate [B].

○

Remove:

Breather Plate Bolts [C]
Breather Plate with Pipe [D]

Crankcase Assembly

NOTICE

The upper and lower crankcase halves are ma-
chined at the factory in the assembled state, so the
crankcase halves must be replaced as a set.

•

With a high flash-point solvent, clean off the mating sur-
faces of the crankcase halves and wipe dry.

•

Using compressed air, blow out the oil passages in the
crankcase halves.

If the breather plate was removed, install it in the following
procedure.

○

Clean off any oil or dirt and apply liquid gasket to the
breather plate mating surface [A], and then install the
breather plate.

Sealant - Liquid Gasket, TB1216B: 92104-1064

9-12 CRANKSHAFT/TRANSMISSION

Crankcase

•

Apply a non-permanent locking agent to the threads of
the breather plate bolts [A] and tighten them.

Torque - Breather Plate Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)

•

Install:

Shift Drum (see Shift Drum and Fork Installation)
Shift Forks and Shift Rods (see Shift Drum and Fork In-
stallation)
Crankshaft (see Crankshaft Installation)
Balancer Shaft (see Balancer Installation)
Connecting Rods (see Connecting Rod Installation)
Camshaft Chain
Transmission Shafts and Gears (see Transmission Shaft
Installation)
Dowel Pins [A]

•

Before fitting the lower case on the upper case, check the
following.

○

Be sure to hang the camshaft chain on the crankshaft.

○

Check to see that the shift drum and transmission gears
are in the neutral position.

•

Apply liquid gasket [A] to the mating surface of the lower
crankcase half.

Sealant - Liquid Gasket, TB1216B: 92104-1064

NOTICE

Do not apply liquid gasket around the crankshaft
main bearing inserts, and oil passage holes.

•

Fit the lower crankcase to the upper crankcase.

CRANKSHAFT/TRANSMISSION 9-13

Crankcase

•

Apply molybdenum disulfide oil solution to the seating sur-
face [A] and threads [B] of the M8 bolts.

•

Tighten the lower crankcase bolts using the following
steps.

•

Replace the crankcase bolt [A] (M6, L = 135 mm) with a
new one.

○

Following the sequence numbers on the lower crankcase
half, tighten the M8 bolts [1

∼

7] L= 90 mm (3.54 in.).

Torque - Crankcase Bolts (M8): 27.5 N·m (2.80 kgf·m, 20.3

ft·lb)

○

Tighten the M8 bolts [8

∼

9] L= 73 mm (2.87 in.).

Torque - Crankcase Bolts (M8): 23.5 N·m (2.40 kgf·m, 17.3

ft·lb)

○

Tighten the M6 bolts.

Torque - Crankcase Bolts (M6): 11 N·m (1.1 kgf·m, 97 in·lb)

L = 135 mm (5.31 in.) [A]
L = 85 mm (3.35 in.) [B] (with New Copper
Washer)
L = 60 mm (2.36 in.) [C]
L = 38 mm (1.50 in.) [D]

•

Tighten the upper crankcase bolts in the order listed.

Torque - Crankcase Bolts (M6): 11 N·m (1.1 kgf·m, 97 in·lb)

L= 85 mm (3.35 in.) [A]
L= 60 mm (2.36 in.) [B] (with New Copper
Washer)

•

After tightening all crankcase bolts, check the following
items.

○

Wipe up the liquid gasket that seeps out around the
crankcase mating surface.

○

Crankshaft and transmission shafts turn freely.

○

While spinning the output shaft, gears shift smoothly from
the 1st to 6th gear, and 6th to 1st.

○

When the output shaft stays still, the gear can not be
shifted to 2nd gear or other higher gear positions.

•

Install the removed parts (see appropriate chapters).

9-14 CRANKSHAFT/TRANSMISSION

Crankshaft and Connecting Rods

Crankshaft Removal

•

Split the crankcase (see Crankcase Splitting).

•

Remove the crankshaft [A].

Crankshaft Installation

•

Install the crankshaft.

NOTE

○

If the crankshaft is replaced with a new one, refer to the
Connecting Rod Big End Bearing Insert Selection in the
Specifications.

NOTICE

If the crankshaft, bearing inserts, or crankcase
halves are replaced with new ones, select the bear-
ing inserts and check clearance with a plastigage
(press gauge) before assembling engine to be sure
the correct bearing inserts are installed.

○

Align the timing mark [A] on the balancer drive gear [B]
with the timing mark [C] on the balancer gear [D].

•

Apply molybdenum disulfide oil solution to the crankshaft
main bearing inserts.

Connecting Rod Removal

•

Split the crankcase (see Crankcase Splitting).

•

Remove:

Connecting Rod Big End Nuts [A]

NOTE

○

Mark and record the locations of the connecting rods
and their big end caps so that they can be reassembled
in their original positions.

•

Remove the connecting rods from the crankshaft.

NOTICE

Discard the connecting rod bolts. To prevent dam-
age to the crankpin surfaces, do not allow the con-
necting rod bolts to bump against the crankpins.

CRANKSHAFT/TRANSMISSION 9-15

Crankshaft and Connecting Rods

Connecting Rod Installation

NOTICE

To minimize vibration, the connecting rods should
have the same weight mark.

Big End Cap [A]
Connecting Rod [B]
Weight Mark, Alphabet [C]
Diameter Mark (Around Weight Mark) [D]: "

○

" or no

mark

NOTICE

If the connecting rods, big end bearing inserts, or
crankshaft are replaced with new ones, select the
bearing insert and check clearance with a plasti-
gage (press gauge) before assembling engine to be
sure the correct bearing inserts are installed.

NOTICE

The connecting rod bolts are designed to stretch
when tightened. Never reuse them.

•

Replace the connecting rod big end bolts and nuts with
new ones.

•

Apply molybdenum disulfide oil solution to the inner sur-
faces of upper and lower bearing inserts [A].

○

Do not apply any grease or oil to the cap inside and cap
insert outside [B].

○

Install the inserts so that their nails [C] are on the same
side and fit them into the recess of the connecting rod and
cap.

NOTICE

Wrong application of oil and grease could cause
bearing damage.

○

When installing the inserts [A], be careful not to damage
the insert surface with the edge of the connecting rod [B]
or the cap [C]. One way to install inserts is as follows.

Installation [D] to Cap
Installation [E] to Connecting Rod
Push [F]
Spare Dowel Pin [G]
Connecting Rod Bolts [H]

•

Install the cap on the connecting rod, aligning the weight
and diameter marks.

•

Remove debris and clean the surface of inserts.

9-16 CRANKSHAFT/TRANSMISSION

Crankshaft and Connecting Rods

•

Install each connecting rod on its original crankpin.

○

The connecting rod big end is bolted using the “plastic
region fastening method”.

○

This method precisely achieves the needed clamping
force without exceeding it unnecessarily, allowing the
use of thinner, lighter bolts further decreasing connecting
rod weight.

○

There are two types of the plastic region fastening. One is
a bolt length measurement method and other is a rotation
angle method. Observe one of the following two, but the
bolt length measurement method is preferable because
this is a more reliable way to tighten the big end nuts.

NOTICE

The connecting rod bolts are designed to stretch
when tightened. Never reuse the connecting rod
bolts. See the table below for correct bolt and nut
usage.

NOTICE

Be careful not to overtighten the nuts.
The bolts must be positioned on the seating surface
correctly to prevent the bolt heads from hitting the
crankcase.

(1) Bolt Length Measurement Method

•

Be sure to clean the bolts, nuts, and connecting rods
thoroughly with a high flash-point solvent, because the
new connecting rods, bolts, and nuts are treated with an
anti-rust solution.

WARNING

Gasoline and low flash-point solvents can be
flammable and/or explosive and cause severe
burns. Clean the bolts, nuts, and connecting rods
in a well-ventilated area, and take care that there
are no sparks or flame anywhere near the working
area; this includes any appliance with a pilot light.
Do not use gasoline or a low flash-point solvent to
clean them.

NOTICE

Immediately dry the bolts and nuts with com-
pressed air after cleaning. Clean and dry the bolts
and nuts completely.

CRANKSHAFT/TRANSMISSION 9-17

Crankshaft and Connecting Rods

•

Install new bolts and nuts in reused connecting rod.
If the connecting rod assy was replaced, use the new bolts
and nuts attached to the new connecting rod assy.

•

Apply a small amount of molybdenum disulfide oil solution
to the following portions.

Threads [A] of Nuts and Bolts
Seating Surfaces [B] of Nuts and Connecting Rods

•

Dent both bolt head and bolt tip with a punch as shown.

•

Before tightening, use a point micrometer to measure the
length of new connecting rod bolts and record the values
to find the bolt stretch.

Connecting Rod [A]
Dent here with a punch [B].
Nuts [C]
Fit micrometer pins into dents [D].

•

Tighten the big end nuts until the bolt elongation reaches
the length specified as follows.

Bolt Length after

tightening

–

Bolt Length before

tightening

Bolt Stretch

Connecting Rod Bolt Stretch

Usable Range:

0.15

∼

0.25 mm (0.0059

∼

0.0098 in.)

•

Check the length of the connecting rod bolts.
If the stretch is more than the usable range, the bolt has
stretched too much. An overelongated bolt may break in
use.

(2) Rotation Angle Method

If you do not have a point micrometer, you may tighten
the nuts using the “Rotation Angle Method”.

•

Be sure to clean the bolts, nuts and connecting rods thor-
oughly with a high flash-point solvent, because the new
connecting rods, bolts and nuts are treated with an anti
-rust solution.

WARNING

NOTICE

Immediately dry the bolts and nuts with com-
pressed air after cleaning.
Clean and dry the bolts and nuts completely.

9-18 CRANKSHAFT/TRANSMISSION

Crankshaft and Connecting Rods

•

Install new bolts and nuts in reused connecting rod.
If the connecting rod assy was replaced, use the new bolts
and nuts attached to the new connecting rod assy.

•

Apply a small amount of molybdenum disulfide oil solution
to the following portions.

Threads [A] of Nuts and Bolts
Seating Surfaces [B] of Nuts and Connecting Rods

•

First, tighten the nuts with

10.0 N·m (1.02 kgf·m, 89 in·lb)

of torque.

•

Next, tighten the nuts

120°

○

Mark [A] the connecting rod big end caps and nuts so that
nuts can be turned 120° [B] properly.

Connecting

Rod Assy

Bolt

Nut

Torque + Angle

N·m (kgf·m, in·lb)

Attached to
new con-rod

Attached to

new con-rod

New

10.0 (1.02, 89)

+ 120°

Used

Replace the
bolts with
new ones

Replace the
nuts with new
ones

10.0 (1.02, 89)

+ 120°

○

The nuts can be tightened by using a torque angle gauge
[A].

Crankshaft/Connecting Rod Cleaning

•

After removing the connecting rods from the crankshaft,
clean them with a high flash-point solvent.

•

Blow the crankshaft oil passages with compressed air to
remove any foreign particles or residue that may have
accumulated in the passages.

CRANKSHAFT/TRANSMISSION 9-19

Crankshaft and Connecting Rods

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 connect-
ing rod big end, and insert the arbor through the connect-
ing rod big end.

•

Select an arbor of the same diameter as the piston pin
and at least 100 mm (3.94 in.) long, and insert the arbor
[B] through the connecting rod small end.

•

On a surface plate, set the big-end arbor on V block [C].

•

With the connecting rod held vertically, use a height
gauge to measure the difference in the height of the
arbor above the surface plate over a 100 mm (3.94 in.)
length to determine the amount of connecting rod bend.
If the connecting rod bend exceeds the service limit, the
connecting rod must be replaced.

Connecting Rod Bend

Service Limit: TIR 0.2/100 mm (0.008/3.94 in.)

Connecting Rod Twist Inspection

•

With the big-end arbor [A] still on V block [C], hold the
connecting rod horizontally and measure the amount that
the arbor [B] varies from being paralleled with the surface
plate over a 100 mm (3.94 in.) length of the arbor to de-
termine the amount of connecting rod twist.
If the connecting rod twist exceeds the service limit, the
connecting rod must be replaced.

Connecting Rod Twist

Service Limit: TIR 0.2/100 mm (0.008/3.94 in.)

Connecting Rod Big End Side Clearance

Inspection

•

Measure the connecting rod big end side clearance.

○

Insert a thickness gauge [A] between the big end and ei-
ther crank web to determine clearance.

Connecting Rod Big End Side Clearance

Standard:

0.13

∼

0.38 mm (0.0051

∼

0.0150 in.)

Service Limit: 0.58 mm (0.023 in.)

If the clearance exceeds the service limit, replace the con-
necting rod with new one and then check the clearance
again. If the clearance is too large after connecting rod
replacement, the crankshaft also must be replaced.

9-20 CRANKSHAFT/TRANSMISSION

Crankshaft and Connecting Rods

Connecting Rod Big End Bearing Insert/Crankpin

Wear Inspection

•

Measure the bearing insert/crankpin [A] clearance with
plastigage [B].

•

Tighten the big end nuts to the specified torque (see Con-
necting Rod Installation).

NOTE

○

Do not move the connecting rod and crankshaft during
clearance measurement.

Connecting Rod Big End Bearing Insert/Crankpin
Clearance

Standard:

0.032

∼

0.066 mm (0.0013

∼

0.0026 in.)

Service Limit: 0.10 mm (0.0039 in.)

If the clearance is within the standard, no bearing replace-
ment is required.
If the clearance is between 0.066 mm (0.0026 in.) and
the service limit 0.10 mm (0.0039 in.), replace the bear-
ing inserts [A] with inserts painted blue [B]. Check the in-
sert/crankpin clearance with the plastigage. The clear-
ance may exceed the standard slightly, but it must not be
less than the minimum in order to avoid bearing seizure.
If the clearance exceeds the service limit, measure the
diameter of the crankpins.

Crankpin Diameter

Standard:

29.984

∼

30.000 mm (1.1805

∼

1.1811 in.)

Service Limit: 29.97 mm (1.1799 in.)

If any crankpin has worn past the service limit, replace the
crankshaft with a new one.
If the measured crankpin diameters are not less than the
service limit, but do not coincide with the original diameter
markings on the crankshaft, make new marks on it.

Crankpin Diameter Marks

None: 29.984

∼

29.994 mm (1.1805

∼

1.1809 in.)

○

29.995

∼

30.000 mm (1.1809

∼

1.1811 in.)

◊

: Crankpin Diameter Marks, "

○

" or no mark.

CRANKSHAFT/TRANSMISSION 9-21

Crankshaft and Connecting Rods

•

Measure the connecting rod big end inside diameter, and
mark each connecting rod big end in accordance with the
inside diameter.

•

Tighten the connecting rod big end nuts to the specified
torque (see Connecting Rod Installation).

NOTE

○

The mark already on the big end should almost coincide
with the measurement.

Connecting Rod Big End Inside Diameter Marks

None: 33.000

∼

33.008 mm (1.2992

∼

1.2995 in.)

○

33.009

∼

33.016 mm (1.2996

∼

1.2998 in.)

Big End Cap [A]
Connecting Rod [B]
Weight Mark, Alphabet [C]
Diameter Mark (Around Weight Mark) [D]: "

○

" or no

mark

•

Select the proper bearing insert [A] in accordance with the
combination of the connecting rod and crankshaft coding.

Size Color [B]

Bearing Insert

Con-rod Big

End Inside

Diameter

Marking

Crankpin

Diameter

Marking

Size Color

Part Number

None

○

Brown

92139-0784

None

○

Black

92139-0783

○

None

Blue

92139-0782

•

Install the new inserts in the connecting rod and check
insert/crankpin clearance with the plastigage.

Crankshaft Side Clearance Inspection

•

Insert a thickness gauge [A] between the crankcase main
bearing and the crank web at the No. 2 journal [B] to
determine clearance.
If the clearance exceeds the service limit, replace the
crankcase halves as a set.

NOTE

○

The upper and lower crankcase halves are machined
at the factory in the assembled state, so the crankcase
halves must be replaced as a set.

Crankshaft Side Clearance

Standard:

0.05

∼

0.20 mm (0.0020

∼

0.0079 in.)

Service Limit: 0.40 mm (0.0157 in.)

9-22 CRANKSHAFT/TRANSMISSION

Crankshaft and Connecting Rods

Crankshaft Runout Inspection

•

Measure the crankshaft runout.
If the measurement exceeds the service limit, replace the
crankshaft.

Crankshaft Runout

Standard:

TIR 0.02 mm (0.0008 in.) or less

Service Limit: TIR 0.05 mm (0.0020 in.)

Crankshaft Main Bearing Insert/Journal Wear

Inspection

•

Using a plastigage (press gauge), measure the bearing
insert/journal [B] clearance [A].

NOTE

○

Tighten the crankcase bolts to the specified torque (see
Crankcase Assembly).

○

Do not turn the crankshaft during clearance measure-
ment.

○

Journal clearance less than 0.025 mm (0.00098 in.) can
not be measured by plastigage, however, using genuine
parts maintains the minimum standard clearance.

Crankshaft Main Bearing Insert/Journal Clearance

Standard:

0.016

∼

0.048 mm (0.0006

∼

0.0019 in.)

Service Limit: 0.08 mm (0.0031 in.)

If the clearance is within the standard, no bearing replace-
ment is required.
If the clearance is between 0.048 mm (0.0019 in.) and
the service limit 0.08 mm (0.0031 in.), replace the bear-
ing inserts [A] with inserts painted yellow [B]. Check in-
sert/journal clearance with the plastigage. The clearance
may exceed the standard slightly, but it must not be less
than the minimum in order to avoid bearing seizure.
If the clearance exceeds the service limit, measure the
diameter of the crankshaft main journal.

Crankshaft Main Journal Diameter

Standard:

27.984

∼

28.000 mm (1.1017

∼

1.1024 in.)

Service Limit: 27.96 mm (1.101 in.)

If any journal has worn past the service limit, replace the
crankshaft with a new one.
If the measured journal diameters are not less than the
service limit, but do not coincide with the original diameter
markings on the crankshaft, make new marks on it.

Crankshaft Main Journal Diameter Marks

None: 27.984

∼

27.992 mm (1.1017

∼

1.1020 in.)

27.993

∼

28.000 mm (1.1021

∼

1.1024 in.)

□

: Crankshaft Main Journal Diameter Marks, "1" or no

mark.

CRANKSHAFT/TRANSMISSION 9-23

Crankshaft and Connecting Rods

•

Measure the main bearing inside diameter, and mark the
upper crankcase half in accordance with the inside diam-
eter.

[A]: Crankcase Main Bearing Inside Diameter Marks,
"

○

" or no mark.

NOTE

○

Tighten the crankcase bolts to the specified torque (see
Crankcase Assembly).

○

The mark already on the upper crankcase half should
almost coincide with the measurement.

Crankcase Main Bearing Inside Diameter Marks

○

31.000

∼

31.008 mm (1.2205

∼

1.2208 in.)

None: 31.009

∼

31.016 mm (1.2208

∼

1.2211 in.)

•

Select the proper bearing insert [A] in accordance with the
combination of the crankcase and crankshaft coding.

Size Color [B]

Bearing Insert*

Crankcase Main

Bearing Inside

Diameter Marking

Crankshaft Main

Journal Diameter

Marking

Size Color

Part Number

Journal Nos.

92139-0787

1, 3

○

Black

92139-0791

None

92139-0786

1, 3

○

None

Blue

92139-0790

92139-0788

1, 3

None

Yellow

92139-0792

*: The bearing insert for Nos. 2 journal have an oil groove.

•

Install the new inserts in the crankcase halves and check
insert/journal clearance with the plastigage.

9-24 CRANKSHAFT/TRANSMISSION

Starter Motor Clutch

Starter Motor Clutch Removal/Installation

•

Refer to the Alternator Rotor Removal/Installation in the
Electrical System chapter.

Starter Motor Clutch Inspection

•

Remove:

Alternator Cover (see Alternator Cover Removal in the
Electrical System chapter)
Starter Idle Gear and shaft

•

Turn the starter motor clutch gear [A] by hand. The starter
motor clutch gear should turn clockwise [B] freely, but
should not turn counterclockwise [C].
If the starter motor clutch does not operate as it should or
if it makes noise, go to the next step.

•

Disassemble the starter motor clutch, and visually inspect
the clutch parts.
If there is any worn or damaged part, replace it.

NOTE

○

Examine the starter motor clutch gear as well. Replace
it if it worn or damaged.

Starter Motor Clutch Disassembly

•

Remove:

Alternator Rotor (see Alternator Rotor Removal in the
Electrical System chapter)
Starter Motor Clutch Bolts [A]
Starter Motor Clutch [B]

Starter Motor Clutch Assembly

•

Apply a non-permanent locking agent to the threads of
the starter motor clutch bolts and tighten them.

Torque - Starter Motor Clutch Bolts: 34.3 N·m (3.50 kgf·m,

25.3 ft·lb)

CRANKSHAFT/TRANSMISSION 9-25

Balancer

Balancer Removal

•

Split the crankcase (see Crankcase Splitting).

•

Remove the balancer shaft [A] with the balancer gear.

Balancer Installation

•

Install the balancer shaft.

○

Align the timing mark [A] on the balancer gear [B] with the
timing mark [C] on the balancer drive gear [D].

•

Apply molybdenum disulfide oil solution to the balancer
shaft bearing inserts.

Balancer Shaft Bearing Insert/Journal Wear

Inspection

•

Measure the bearing insert/journal [A] clearance with
plastigage [B].

NOTE

○

Tighten the crankcase bolts to the specified torque (see
Crankcase Assembly).

○

Do not turn the balancer shaft during clearance mea-
surement.

○

Journal clearance less than 0.025 mm (0.00098 in.) can
not be measured by plastigage, however, using genuine
parts maintains the minimum standard clearance.

Balancer Shaft Bearing Insert/Journal Clearance

Standard:

0.014

∼

0.050 mm (0.0006

∼

0.0020 in.)

Service Limit: 0.08 mm (0.0031 in.)

If the clearance is within the standard, no bearing replace-
ment is required.
If the clearance is between 0.050 mm (0.0020 in.) and the
service limit 0.08 mm (0.0031 in.), replace the bearing in-
serts [A] with inserts painted blue [B]. Check insert/journal
clearance with the plastigage. The clearance may exceed
the standard slightly, but it must not be less than the min-
imum in order to avoid bearing seizure.
If the clearance exceeds the service limit, measure the
diameter of the balancer shaft journal.

Balancer Shaft Journal Diameter

Standard:

25.984

∼

26.000 mm (1.0230

∼

1.0236 in.)

Service Limit: 25.96 mm (1.022 in.)

9-26 CRANKSHAFT/TRANSMISSION

Balancer

If any journal has worn past the service limit, replace the
balancer shaft with a new one.
If the measured journal diameters are not less than the
service limit, but do not coincide with the original diameter
markings [A] on the balancer shaft, make new marks on
it.

Balancer Shaft Journal Diameter Marks

None: 25.984

∼

25.994 mm (1.0230

∼

1.0234 in.)

○

25.995

∼

26.000 mm (1.0234

∼

1.0236 in.)

: Balancer Shaft Journal Diameter Marks, "

○

" or no

mark.

•

Measure the main bearing inside diameter, and mark the
upper crankcase half in accordance with the inside diam-
eter.

[A]: Balancer Shaft Bearing Inside Diameter Marks, "

○

or no mark.

NOTE

○

Tighten the crankcase bolts to the specified torque (see
Crankcase Assembly).

○

The mark already on the upper crankcase half should
almost coincide with the measurement.

Balancer Shaft Bearing Inside Diameter Marks

○

29.000

∼

29.008 mm (1.1417

∼

1.1420 in.)

None: 29.009

∼

29.016 mm (1.1421

∼

1.1424 in.)

•

Select the proper bearing insert [A] in accordance with the
combination of the crankcase and balancer shaft coding.

Size Color [B]

Bearing Insert

Balancer

Shaft Journal

Diameter

Marking

Balancer Shaft

Bearing Inside

Diameter

Marking

Size Color

Part Number

○

Brown

92028-1424

○

None

○

Black

92028-1423

None

Blue

92028-1422

•

Install the new inserts in the crankcase and check in-
sert/journal clearance with the plastigage.

CRANKSHAFT/TRANSMISSION 9-27

Transmission

Shift Pedal Removal

•

Remove:

Shift Pedal Mounting Bolt [A]
Shift Lever Bolt [B]
Shift Pedal [C] with Shift Lever

Shift Pedal Installation

•

Apply grease to the shift pedal [A].

•

Install the washers [B] and shift pedal.

•

Apply a non-permanent locking agent to the threads of
the shift pedal mounting bolt [C].

•

Tighten:

Torque - Shift Pedal Mounting Bolt: 12 N·m (1.2 kgf·m, 106

in·lb)

•

Align the mark [A] on the shift shaft with the mark [B] on
the shift lever.

•

Tighten:

Torque - Shift Lever Bolt: 12 N·m (1.2 kgf·m, 106 in·lb)

•

Install the shift pedal [C] as shown.

About 20.5° [D]

○

The lower end of shift pedal is positioned in the center of
the tie-rod.

○

To adjust the pedal position, loosen the front locknut [E]
(left-hand threads) and rear locknut [F] and then turn the
tie-rod [G].

•

Tighten:

Torque - Tie-Rod Locknuts: 9.8 N·m (1.0 kgf·m, 87 in·lb)

9-28 CRANKSHAFT/TRANSMISSION

Transmission

•

Be sure the sealing lip of the rubber boots [A] fits into the
groove of the ball joint after installing the shift lever link.

Correctly Boot Fitting Position [B]
Incorrectly Boot Fitting Position [C]

External Shift Mechanism Removal

•

Drain:

Engine Oil (see Engine Oil Change in the Periodic Main-
tenance chapter)

•

Remove:

Shift Lever (see Shift Pedal Removal)
Clutch (see Clutch Removal in the Clutch chapter)

•

Spread the shift mechanism arm [A] and over shift limiter
[B] out of the shift drum [C], and pull out the shift shaft
assembly [D].

External Shift Mechanism Installation

•

Check that the return spring [A] and pawl spring [B] are
properly fitted on the mechanism.

•

Install the shift shaft assembly.

•

Place the shift mechanism arm [C] and over shift limiter
[D] on the shift drum pins.

•

Install the removed parts (see appropriate chapters).

External Shift Mechanism Inspection

•

Examine the shift shaft [A] for any damage.
If the shaft is bent, straighten or replace it.
If the splines [B] are damaged, replace the shaft.
If the return spring [C] or pawl spring [D] is damaged in
any way, replace them.
If the shift mechanism arm [E] or over shift limiter [F] is
damaged in any way, replace the shaft.

9-30 CRANKSHAFT/TRANSMISSION

Transmission

•

Apply engine oil to the bearings.

○

The bearing set pins and rings must match properly with
the holes or grooves in the bearing outer races. When
they are properly matched, there is no clearance [A] be-
tween the crankcase and the bearing outer races.

•

Assemble the crankcase (see Crankcase Assembly).

•

Press in the oil seal [A] onto collar [B] so that the surface
of the oil seal is flush with the counterbore bottom surface
[C] of the crankcase.

○

Apply grease to the oil seal lips.

Transmission Shaft Disassembly

•

Remove the transmission shafts (see Transmission Shaft
Removal).

•

Remove the circlips, disassemble the transmission
shafts.

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 mecha-
nism. Remove the 5th gear.

○

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

○

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

•

Remove the ball bearing [A] from each shafts.

Special Tools - Bearing Puller [B]: 57001-135

Bearing Puller Adapter [C]: 57001-317

•

Discard the bearing.

CRANKSHAFT/TRANSMISSION 9-31

Transmission

Transmission Shaft Assembly

•

Apply engine oil to the bushings, ball bearings and shafts.

•

Install the ball bearings on the shafts with the groove to-
ward the clutch side.

•

Install the gear bushings [A] on the shaft with their holes
[B] aligned.

•

Replace any circlips removed with new ones.

•

Install the circlips [A] so that the opening [B] is aligned
with a spline groove [C].

•

The drive shaft gears can be recognized by size: the gear
with the smallest diameter is 1st gear, and the largest one
is 6th gear. Be sure that all parts are put back in the cor-
rect sequence and all circlips and washers are properly in
place.

•

Install the 6th gear bushing onto the drive shaft with their
oil holes aligned.

•

The output shaft gears can be recognized by size: the
gear with the largest diameter is 1st gear, and the small-
est one is 6th gear. Be sure that all parts are put back
in the correct sequence and all circlips and washers are
properly in place.

•

Install the 6th gear onto the output shaft with their oil holes
aligned.

•

Install the 2nd and 3rd/4th gear bushings onto the output
shaft with their oil holes aligned.

•

Fit the steel balls into the 5th gear holes in the output
shaft, aligning oil hole as shown.

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

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 doesn’t come out of the output shaft when moving it
up and down by hand.

•

Check that each gear spins or slides freely on the trans-
mission shafts without binding after assembly.

Kawasaki Ninja 300 / Ninja 300 ABS Motorcycle. Service Manual (2013) - page 10