Kawasaki Ninja ZX-12R Motorcycle. Service Manual (2002-2005 year)

CRANKSHAFT/TRANSMISSION 9-11

Crankshaft and Connecting Rods

Crankshaft Removal

•

Split the crankcase (see Crankcase Splitting).

•

Remove the crankshaft.

Crankshaft Installation

CAUTION

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

•

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

•

Install the crankshaft with the camshaft chain [A] hanging
on it.

•

Assemble the crankcase (see Crankcase Assembly).

Connecting Rod Removal

•

Split the crankcase (see Crankcase Splitting).

•

Remove the connecting rod nuts [A].

•

Remove the crankshaft.

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.

Connecting Rod Installation

WARNING

Clean the crankshaft, bolts, nuts, and connecting
rods in a well-ventilated area, and take care that
there is no spark or flame anywhere near the work-
ing area. This includes any appliance with a pilot
light. Because of the danger of highly flammable
liquids, do not use gasoline or low-flash point sol-
vents to clean them.

•

After removing the connecting rods from the crankshaft,
clean them with 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.

9-12 CRANKSHAFT/TRANSMISSION

Crankshaft and Connecting Rods

CAUTION

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 [D]

If the connecting rods, big end bearing inserts, or crank-
shaft are replaced with new ones, select the bearing insert
and check clearance with a plastigage before assembling
engine to be sure the correct bearing inserts are installed.

CAUTION

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

•

Apply grease and oil to the following portions.

Apply molybdenum disulfide grease [A].
Do not apply grease and oil [B].
Apply molybdenum disulfide oil solution [C].

CAUTION

Do not apply grease to the inner surface of the lower
big end cap or to the outer surface of the lower bear-
ing insert.

•

Install the bearing insert as shown to prevent it’s outer
surface from scratch damage with connecting rod edge.

Connecting Rod Side Bearing Insert [A]
Dowel Pin [B]
Claw Side [C]
Cap Side Bearing Insert [D]
Connecting Rod Cap [E]

•

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

•

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

CAUTION

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

CRANKSHAFT/TRANSMISSION 9-13

Crankshaft and Connecting Rods

•

Apply small amount of molybdenum disulfide oil solution
to the threads [A] and seating surfaces [B] of the connect-
ing rod nuts.

•

First, tighten the nuts to the specified torque. See the
table below.

•

Next, tighten the nuts by

120°

more.

○

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

○

Tighten the hexagon nut by 2 corners.

Connecting

Rod Assy

Bolt, Nut

Torque + Angle

N·m (kgf·m, ft·lb)

Use the bolts attached to
new con-rod.

21.6 (2.2, 16) + 120°

New

Another new bolts and
nuts

21.6 (2.2, 16) + 120°

Used

Replace the bolts and
nuts with new ones

21.6 (2.2, 16) + 120°

CAUTION

Since the friction force of the seating surface and
thread portion of new nuts is different from that
of used ones, the nut tightening torque should be
changed as specified in the above table.
Be careful not to overtighten the nuts.

Connecting Rod Bend

•

Remove the connecting rod big end bearing inserts, and
reinstall the connecting rod big end caps.

•

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
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 blocks [C].

•

Measure the difference in the heights of the arbor above
the surface plate over a 100 mm (3.94 in.) distance-on
the arbor to determine the amount of connecting rod bend
with the connecting rod held vertically, and using a height
gauge.
If connecting rod bend exceeds the service limit, the con-
necting rod must be replaced.

Connecting Rod Bend

Service Limit:

0.2/100 mm (0.008/3.94 in.)

9-14 CRANKSHAFT/TRANSMISSION

Crankshaft and Connecting Rods

Connecting Rod Twist

•

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

•

Measure the difference in the heights of the arbor above
the surface plate over a 100 mm (3.94 in.) distance-on the
arbor to determine the amount of connecting rod twist with
the connecting rod held horizontally, and using a height
gauge.
If connecting rod twist exceeds the service limit, the con-
necting rod must be replaced.

Connecting Rod Twist

Service Limit:

0.2/100 mm (0.008/3.94 in.)

Connecting Rod Big End Side Clearance

•

Measure connecting rod big end side clearance [A].

○

Insert a thickness gauge [B] 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 clearance again
If clearance is too large after connecting rod replacement,
the crankshaft also must be replaced.

Connecting Rod Big End Bearing Insert/Crankpin

Wear

•

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

NOTE

○

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

○

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

Connecting Rod Big End Bearing Insert/Crankpin
Clearance

Standard:

0.048

∼

0.084 mm (0.0019

∼

0.0033 in.)

Service Limit:

0.10 mm (0.0039 in.)

If clearance is within the standard, no bearing replace-
ment is required.
If clearance is between 0.085 mm (0.0033 in.)

and

the service limit (0.10 mm, 0.0039 in.), replace the
bearing inserts [A] with inserts painted blue [B]. Check
insert/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:

36.984

∼

37.000 mm (1.4561

∼

1.4567

in.)

Service Limit:

36.97 mm (1.456 in.)

CRANKSHAFT/TRANSMISSION 9-15

Crankshaft and Connecting Rods

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

36.984

∼

36.992 mm (1.4561

∼

1.4564 in.)

○

36.993

∼

37.000 mm (1.45641

∼

1.4567 in.)

: Crankpin Diameter Marks, "

○

" mark or no mark.

•

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

Big End Cap [A]
Connecting Rod [B]
Weight Mark [C]: A letter of the alphabet
Bore Diameter Mark (Around Weight Mark) [D]: "

○

" or

no mark.

NOTE

○

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

○

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

Connecting Rod Big End Bore Diameter Marks

None

40.000

∼

40.008 mm (1.5748

∼

1.5751 in.)

○

40.009

∼

40.016 mm (1.5752

∼

1.5754 in.)

•

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

•

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

Bearing Insert

Con-rod Big End

Bore Diameter

Marking

Crankpin
Diameter

Marking

Size Color

Part Number

None

○

Brown

92139-1093

None

○

Black

92139-1092

○

None

Blue

92139-1091

9-16 CRANKSHAFT/TRANSMISSION

Crankshaft and Connecting Rods

Crankshaft Main Bearing Insert/Journal Wear

•

Measure the bearing insert/journal [B] clearance with a
plastigage [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 (0.0010 in.) can
not be measured by plastigage, however, using genuine
parts maintains the minimum standard clearance.

Crankshaft Main Bearing Insert/Journal Clearance

Standard:

0.031

∼

0.063 mm (0.0012

∼

0.0025 in.)

Service Limit: 0.07 mm (0.0031 in.)

If clearance is within the standard, no bearing replace-
ment is required.
If clearance is between 0.064 mm (0.025 in.) and the ser-
vice limit (0.07 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 clearance exceeds the service limit, measure the diam-
eter of the crankshaft main journal.

Crankshaft Main Journal Diameter

Standard:

36.984

∼

37.000 mm (1.4561

∼

1.4567 in.)

Service Limit: 36.96 mm (1.455 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

36.984

∼

36.992 mm (1.4561

∼

1.4564 in.)

36.993

∼

37.000 mm (1.45641

∼

1.4567 in.)

□

: Crankshaft Main Journal Diameter Marks, "1" mark

or no mark.

CRANKSHAFT/TRANSMISSION 9-17

Crankshaft and Connecting Rods

•

Measure the main bearing bore diameter, and mark [B]
the upper crankcase half [A] in accordance with the bore
diameter.

○

Crankcase main bearing bore diameter marks are "

○

mark and 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 Bore Diameter Marks

○

40.000

∼

40.008 mm (1.5748

∼

1.5751 in.)

None

40.009

∼

40.016 mm (1.5752

∼

1.5754 in.)

•

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

•

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

Bearing Insert*

Crankcase Main

Bearing Bore

Diameter Marking

Crankshaft Main

Journal Diameter

Marking

Size Color

Part Number

Journal Nos.

92028-1997

1, 5

○

Brown

92139-1055

92139-1052

2, 4

○

None

92028-1996

1, 5

Black

92139-1054

None

92139-1051

2, 4

92028-1995

1, 5

None

Blue

92139-1053

92028-1998

2, 4

*The bearing inserts for Nos. 2, 3 and 4 journals have an oil groove, respectively.

Crankshaft Side Clearance

•

Situate the motorcycle so that it is perpendicular to the
ground.

•

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

CAUTION

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.

Crankshaft Side Clearance

Standard:

0.05

∼

0.20 mm (0.0020

∼

0.0079 in.)

Service Limit:

0.40 mm (0.016 in.)

CRANKSHAFT/TRANSMISSION 9-19

Balancer

Balancer Removal

•

Split the crankcase (see Crankcase Splitting).

•

Remove:

Crankshaft
Driveshaft

•

Unscrew the balancer shaft clamp bolt [A], and balancer
shaft clamp lever bolt [B], and pull off the clamp lever [C].

•

Pull the balancer shaft [D] out of the crankcase. The bal-
ancer weight and gear assembly [E] come off with the
needle bearings and copper washers.

Balancer Installation

•

Check that the rubber dampers [A] are in place as shown.

•

Apply molybdenum disulfide oil solution to the damper
contact portions of the balancer weight.

•

Install the balancer weight [A] into the gear [B].

○

Align the mark [C] of the balancer weight to the groove
[D] of the gear.

•

Apply molybdenum disulfide oil solution to the needle
bearings. Insert the needle bearings.

•

Fit the copper washers [A] on both ends of the weight and
gear assembly. The projected sides [B] face inward.

•

Set the weight and gear assembly to the Lower
Crankcase.

•

Apply engine oil to the O-ring of the balancer shaft.

•

Insert the balancer shaft.

•

Turn the balancer shaft, so the punch mark [A] comes
toward the oil pan [B], and then install the clamp lever
[C].

•

Tighten the balancer shaft lever bolt [D] and tighten the
clamp bolt [E].

Torque - Balancer Shaft Clamp Lever Bolt: 25 N·m (2.5

kgf·m, 18 ft·lb)

Balancer Shaft Clamp Bolt: 12 N·m (1.2 kgf·m, 106

in·lb)

9-20 CRANKSHAFT/TRANSMISSION

Balancer

•

Position the crankshaft at #1, 4 position TDC.

•

Fit the lower crankcase to the upper crankcase aligning
the punch mark [A] on the balancer weight with the pro-
jection [B] of the lower crankcase.

•

Adjust the balancer gear backlash with the engine idling.
The amount of backlash can be changed by turning the
balancer shaft which has eccentric journals.

○

Remove the right lower fairing (see Frame chapter).

○

Start the engine and let it idle.

○

Loosen the clamp bolt [A] and turn the balancer shaft [B]
clockwise [C] until the balancer gear makes a whining
sound.

○

Turn the shaft counter-clockwise [D] until the balancer
gear whining sound disappears and tighten the clamp
bolt.

Torque - Balancer Shaft Clamp Bolt: 12 N·m (1.2 kgf·m, 106

in·lb)

Balancer Damper Inspection

•

Remove the balancer and disassemble the weight and
gear assembly.

•

Visually inspect the rubber dampers [A].
If they appear damaged or deteriorated, replace them.

CRANKSHAFT/TRANSMISSION 9-21

Starter Motor Clutch and Torque Limiter

Starter Motor Removal/Installation

•

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

Starter Motor Clutch Removal

•

Split the crankcase (see Crankcase Splitting).

•

Remove:

Transmission Shafts
Crankshaft

•

Unscrew the starter clutch shaft plate bolt [A].

•

Pull the starter clutch shaft bolt [C] with the stopper plate
[D] and starter clutch shaft holding the starter clutch [B].

•

Remove the starter clutch.

Starter Motor Clutch Installation

•

Apply engine oil to the needle bearing.

•

Install:

Coller (Long) [A]
Starter Motor Clutch [B]
Coller (Short) [C]
Starter Motor Clutch Shaft [D]

○

Apply molybdenum disulfide grease to the starter motor
clutch shaft.

•

Apply a non-permanent locking agent to the threads of
the starter clutch shaft plate bolt, and tighten it.

Torque - Starter Clutch Shaft Plate Bolt: 12 N·m (1.2 kgf·m,

106 in·lb)

If the shaft bolt removed, tighten it.

○

Apply a non-permanent locking agent to the threads of
the shaft bolt.

Torque - Starter Clutch Shaft Bolt: 25 N·m (2.5 kgf·m, 18

ft·lb)

Starter Motor Clutch Disassembly

•

Remove the starter motor clutch.

•

Pull the driven gear out off from the drive gear.

•

Remove:

Circlip [A]
Flat Washer [B]

9-22 CRANKSHAFT/TRANSMISSION

Starter Motor Clutch and Torque Limiter

•

Holding the drive gear [A] with a hand, take off the one
-way clutch [B] from the gear by using the screw driver
[C].

Starter Motor Clutch Assembly

•

Be sure to install the one-way clutch [A] so that its flange
[B] fits in the holder recess [C].

•

Turn in the driven gear [A] to the drive gear [B].

Counterclockwise [C]

Starter Clutch Inspection

•

Remove the engine (see Engine Removal/Installation
chapter).

•

Remove:

Cooling Hose Fitting (see Cooling System chapter)
Starter Motor (see Electrical System chapter)
Bolts [A]
Torque Limiter Cover [B]

•

Turn the starter idle gear [A] by hand. When viewed from
the rear side of the engine, the starter idle gear should
turn forward [B] freely, but should not turn backward [C].
If the clutch does not operate as it should or if it makes
noise, disassemble the starter clutch, examine each part
visually, and replace any worn or damaged parts.

CRANKSHAFT/TRANSMISSION 9-23

Starter Motor Clutch and Torque Limiter

Torque Limiter Removal

•

Remove:

Starter Motor (see Electrical System chapter)
Torque Limiter Cover (see Starter Motor Clutch Inspec-
tion)

•

Using the 5 mm (0.20 in.) bolt [A], pull out the torque
limiter shaft [B].

•

Remove the torque limiter [C].

Torque Limiter Installation

•

Inspect the O-ring, and replace it if it is damaged.

•

Apply engine oil to the O-ring.

•

Apply molybdenum disulfide grease to the torque limiter
shaft.

•

Install the torque limiter cover bolts with clamps [A] as
shown.

○

Apply a non-permanent locking agent to the bolts.

Torque - Torque Limiter Cover Bolts: 12 N·m (1.2 kgf·m, 106

in·lb)

9-24 CRANKSHAFT/TRANSMISSION

Transmission

Shift Pedal Removal

•

Mark [A] the position of the shift lever [B] on the shift shaft
so that it can be installed later in the same position.

•

Remove:

Bolt [C]
Shift Lever

•

Remove the bolt [A], and shift pedal [B].

Shift Pedal Installation

•

Apply grease to install the oil seals [A] direction as shown.

•

Apply grease [B] to the bearing portion of the shift pedal
mounting bolt [C].

Washer [D]
Shift Pedal [E]

•

Install the shift pedal [A] so that the center of the shift
pedal front end [B] is aligned with the center line [C] of
the shift rod [D] by loosening the front and rear locknuts
[E], and turning the rod.

NOTE

○

The locknut next to the knurled portion of the rod has
left-hand threads.

If necessary, adjust the pedal position from the standard
position to suit you as follows.

•

Loosen the front and rear rod locknuts.

•

Turn the rod to adjust the pedal position.

•

Tighten the locknuts securely.

CRANKSHAFT/TRANSMISSION 9-25

Transmission

External Shift Mechanism Removal

•

Squeeze the brake lever slowly and hold it with a band
[A].

WARNING

Be sure to hold the front brake when removing the
engine, or the motorcycle, may fall over. If could
cause an accident and injury.

CAUTION

Be sure to hold the front brake when removing the
engine, or the motorcycle may fall over. The engine
or the motorcycle could be damaged.

•

Remove:

Engine Oil (drain, see Engine Oil Change in the Periodic
Maintenance chapter)
Shift Pedal (see Shift Pedal Removal)
Clutch (see Clutch chapter)
Bolts [A], Oil Pipe Holders [B], Oil Pipe [C] with O-ring

•

Remove the shift shaft assembly [A] while pulling the shift
mechanism arm [B] to the direction of the arrow.

•

Remove the oil pump drive gear [A] initially if removing the
gear positioning lever [B] (see Engine Lubrication System
chapter).

•

Remove:

Bolt [C]
Gear Positioning Lever [B]
Spring [D]

9-26 CRANKSHAFT/TRANSMISSION

Transmission

External Shift Mechanism Installation

•

Replace the circlip that was removed with a new one and
install the shift mechanism arm.

•

Install the gear positioning lever [A] as shown.

Spring [B]
Collar [C]
Bolt [D]

•

Apply a non-permanent locking agent to the bolt and
tighten it.

Torque - Gear Positioning Lever Bolt: 10 N·m (1.0 kgf·m, 89

in·lb)

•

Apply engine oil to the O-rings to install the oil pipe.

•

Apply a non-permanent locking agent to the oil pipe holder
bolts and tighten them.

Torque - Oil Pipe Holder Bolts: 12 N·m (1.2 kgf·m, 106 in·lb)

External Shift Mechanism Inspection

•

Examine the shift shaft [A] for any damage.
If the shaft is bent, straighten or replace it.
If the serration are damaged, replace the shaft.
If the springs [B], [C] are damaged in any way, replace
them.
If the shift mechanism arm [D] is damaged in any way,
replace the arm.

•

Check the return spring pin [A] is not loose.
If it is loose, unscrew it, apply a non-permanent locking
agent to the threads, and tighten it.

Torque - Shift Shaft Return Spring Pin: 30 N·m (3.0 kgf·m,

22 ft·lb)

•

Check the gear positioning lever [B] and it spring for
breaks or distortion.
If the lever or spring are damaged in any way, replace
them.

•

Visually inspect the shift drum cam [C].
If they are badly worn or if they show any damage, replace
it.

Transmission Shaft Removal

•

Split the crankcase (see Crankcase Splitting).

•

Remove the drive shaft [A] and output shaft [B].

CRANKSHAFT/TRANSMISSION 9-27

Transmission

Transmission Shaft Installation

•

Apply engine oil to the sliding surfaces of the shafts, gears
and bearings.

•

Check to see that the set pins [A] and set rings [B] are in
place.

•

Install the drive shaft and output shaft into the upper
crankcase half.

○

Install the output shaft [A] first.

○

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 between
the crankcase and the bearing outer races [A].

•

Assemble the crankcase.

•

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

Transmission 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.

9-28 CRANKSHAFT/TRANSMISSION

Transmission

•

Remove the ball bearing [A] from each shafts.

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

Bearing Puller Adapter: 57001-317 [C]

•

Discard the bearing.

Transmission Assembly

•

Apply engine oil to the ball bearing and shaft.

•

Drive the ball bearing onto the drive shaft [A] with the
groove [B] facing the clutch.

•

Drive the ball bearing onto the output shaft.

Special Tool - Steering Stem Bearing Driver: 57001-137

•

Aligne the bushing-oil holes [B] with the shaft-oil holes to
install the gear bushings [A].

•

Replace any circlip that were removed with new ones.

•

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

•

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

•

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 3rd/4th gear onto the drive shaft with their oil
holes aligned.

CRANKSHAFT/TRANSMISSION 9-29

Transmission

1. Circlip (small)
2. Needle Bearing
3. Washer (big)
4. Washers (small)
5. Circlips (big)

6. Outer Race
7. 2nd Gear
8. Bushing (Spline)
9. Top Gear

10. 3rd/4th Gear

11. Bushing

12. 5th Gear
13. Drive Shaft with 1st Gear
14. Ball Bearing

•

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 5th and 6th gear onto the output shaft with their
oil holes aligned as shown.

○

Apply molybdenum disulfide grease to both surfaces of
the No.18 washers (see 9-30 page).

9-30 CRANKSHAFT/TRANSMISSION

Transmission

1. Ball Bearing
2. Washer
3. Circlips
4. Steel Balls
5. Washer
6. Needle Bearing
7. Circlip

8. Output Shaft
9. 2nd Gear

10. Bushing

11. Top Gear

12. 4th Gear
13. Bushings
14. 3rd Gear

15. 5th Gear
16. Needle Bearing
17. 1st Gear
18. Washer
19. Outer Race

•

Fit the steel balls into the 5th gear holes as shown.

View A-A’ (see the output shaft illustration)
Gear (5th) [A]
Shaft [B]
Steel Balls [C]

CAUTION

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

○

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.

Shift Drum and Fork Removal

•

Remove:

Lower Fairings (see Frame chapter)
Muffler (see Engine Top End chapter)
Oil Pan (see Engine Lubrication System chapter)
Oil Pump Drive Gear (see Engine Lubrication System
chapter)
External Shift Mechanism (see External Shift Mecha-
nism Removal)
Gear Position Switch (see Fuel System (DFI) chapter)
Gear Positioning Lever (see External Shift Mechanism
Removal)
Bolt [A] and Screw [B]

CRANKSHAFT/TRANSMISSION 9-31

Transmission

•

Pull the shift rods [A] with the shift drum bearing holder
[B] on, and take off the bearing holder and shift forks.

•

Pull out the shift drum [C] with the ball bearing [D].

Shift Drum and Fork Installation

•

Insert the shift drum.

•

Insert the shift forks into both grooves of the gears and
shift drum, and install the shift rods [A]. The shift rods [A]
are identical.

Drive Shaft Shift Fork [B]
Output Shaft Forks with same shape and size [C]

○

Install each fork so that number-marked side faces right
side of the engine.

Drive Shaft Fork marked with “290” [A]
Output Shaft Forks marked with “291” [B]

•

Insert the bearing holder [B] to the shift fork rods [A] as
shown.

•

Apply a non-permanent locking agent to the threads of
the shift drum bearing holder bolt and screw, and tighten
them.

Torque - Shift Drum Bearing Holder Bolt: 12 N·m (1.2 kgf·m,

106 in·lb)

Shift Drum Bearing Holder Screw: 5.4 N·m (0.55

kgf·m, 48 in·lb)

Shift Drum Disassembly

•

Remove the shift drum (see Shift Drum and Fork Re-
moval).

•

While holding the shift drum with a vise, remove the shift
drum cam holder bolt.

Shift Drum Cam Holder Bolt [A]
Shift Drum Cam [B]
Ball Bearing [C]

9-32 CRANKSHAFT/TRANSMISSION

Transmission

Shift Drum Assembly

•

Be sure to install the dowel pin [A].

○

Align the dowel pin with the hole [B] of the shift drum cam
holder.

•

Apply a non-permanent locking agent to the threads of
the shift drum cam bolt, and tighten it.

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

Shift Fork Bending

•

Visually inspect the shift forks, and replace any fork that is
bent. A bent fork could cause difficulty in shifting, or allow
the transmission to jump out of gear when under power.

90° [A]

Shift Fork/Gear Groove Wear

•

Measure the thickness of the shift fork ears [A], and mea-
sure the width [B] of the gear grooves.
If the thickness of a shift fork ear is less than the service
limit, the shift fork must be replaced.

Shift Fork Ear Thickness

Standard:

5.9

∼

6.0 mm (0.232

∼

0.236 in.)

Service Limit:

5.8 mm (0.228 in.)

If the gear groove is worn over the service limit, the gear
must be replaced.

Gear Groove Width

Standard:

6.05

∼

6.15 mm (0.238

∼

0.242 in.)

Service Limit: 6.25 mm (0.246 in.)

Shift Fork Guide Pin/Drum Groove Wear

•

Measure the diameter of each shift fork guide pin [A], and
measure the width [B] of each shift drum groove.
If the guide pin on any shift fork is less than the service
limit, the fork must be replace.

Shift Fork Guide Pin Diameter

Standard:

6.9

∼

7.0 mm (0.272

∼

0.276 in.)

Service Limit:

6.8 mm (0.268 in.)

If any shift drum groove is worn over the service limit, the
drum must be replaced.

Shift Drum Groove Width

Standard:

7.05

∼

7.20 mm (0.278

∼

0.283 in.)

Service Limit: 7.3 mm (0.287 in.)

WHEELS/TIRES 10-1

Wheels/Tires

Table of Contents

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

10-2

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

10-3

Wheels (Rims) ........................................................................................................................

10-4

Front Wheel Removal .......................................................................................................

10-4

Front Wheel Installation ....................................................................................................

10-4

Rear Wheel Removal........................................................................................................

10-5

Rear Wheel Installation.....................................................................................................

10-6

Wheel Inspection ..............................................................................................................

10-8

Axle Inspection..................................................................................................................

10-8

Balance Inspection............................................................................................................

10-8

Balance Adjustment ..........................................................................................................

10-9

Balance Weight Removal..................................................................................................

10-9

Balance Weight Installation...............................................................................................

10-10

Tires........................................................................................................................................

10-12

Air Pressure Inspection/Adjustment..................................................................................

10-12

Tire Inspection ..................................................................................................................

10-12

Tire Removal.....................................................................................................................

10-12

Tire Installation..................................................................................................................

10-13

Repair ...............................................................................................................................

10-15

Hub Bearings..........................................................................................................................

10-16

Hub Bearing Removal.......................................................................................................

10-16

Hub Bearing Installation....................................................................................................

10-16

Hub Bearing Inspection.....................................................................................................

10-16

WHEELS/TIRES 10-3

Specifications

Item

Standard

Service Limit

Wheels (Rims)

Rim Size:

Front

17 × 3.50

– – –

Rear

17 × 6.00

– – –

Rim Runout:

Axial

TIR 0.5 mm (0.02 in.) or less

TIR 1.0 mm

(0.04 in.)

Radial

TIR 0.8 mm (0.03 in.) or less

TIR 1.0 mm

(0.04 in.)

Axle Runout/100 mm (3.94 in.) 0.05 mm (0.002 in.) or less

0.2 mm (0.008 in.)

Wheel Balance

10 g (0.35 oz) or less

– – –

Balance Weights

10 g (0.35 oz), 20 g (0.71 oz), 30 g (1.06 oz)

– – –

Tires

Air Pressure (when Cold):

Front

Up to 182 kg (401 lb) load:

290 kPa (2.90 kgf/cm², 42 psi)

– – –

Rear

Up to 182 kg (401 lb) load:

290 kPa (2.90 kgf/cm², 42 psi)

– – –

Tread Depth:

Front

DUNLOP: 4.0 mm (0.16 in.)

1 mm (0.04 in.)

(AT, CH,DE)

1.6 mm (0.06 in.)

Rear

DUNLOP: 5.4 mm (0.21 in.)

Up to 130 km/h

(80 mph):

2 mm (0.08 in.)

Over 130 km/h

(80 mph):

3 mm (0.12 in.)

Standard Tires:

Make, Type

Size

Front

DUNLOP, SPORTMAX RADIAL D208FJ

120/70 ZR17

(tubeless)

M/C (58 W)

Rear

DUNLOP SPORTMAX RADIAL D208J

200/50 ZR17

(tubeless)

M/C (75 W)

AT: Republic of Austria

CH: Swiss Confederation

DE: Federal Republic of Germany

Special Tools - Inside Circlip Pliers: 57001-143

Bearing Driver Set: 57001-1129
Jack: 57001-1238
Bearing Remover Head, 25 × 28: 57001-1346
Bearing Remover Shaft, 13: 57001-1377

10-4 WHEELS/TIRES

Wheels (Rims)

Front Wheel Removal

•

Remove:

Lower Fairings (see Frame chapter)
Brake Caliper Mounting Bolts [A]
Refractors [B] (for the US and Canadian Model)
ZX1200-B1/B2 [C]
ZX1200-B3 [D]

∼

•

Loosen:

Right Side Axle Clamp Bolts [A]
Axle [B]

•

Raise the front wheel off the ground.

Special Tool - Jack: 57001-1238 [A]

•

Pull out the axle to the right and drop the front wheel out
of the forks.

CAUTION

Do not lay the wheel down on one of the discs. This
can damage or warp the disc. Place blocks un-
der the wheel so that the disc does not touch the
ground.

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.

•

Fit the collars on the both sides of the hub.

○

The collars are identical.

•

If the axle nut in the left fork leg is removed, install it on
the left fork leg from the left side.

•

Tighten the axle nut.

Torque - Front Axle Nut: 127 N·m (13 kgf·m, 94 ft·lb)

WHEELS/TIRES 10-5

Wheels (Rims)

•

Before tightening the clamp bolts on the right fork leg,
pump the forks up and down [A] 4 or 5 times to allow the
right fork leg to find a neutral position on the front axle.

NOTE

○

Do not apply the front brake during this process to stop
the motorcycle from rolling forward. Put a block in front
of the wheel to stop it from moving.

•

Tighten the right axle clamp bolts [A] to the specified
torque.

○

The tightening sequence is left, right and left side bolt to
prevent from loosening the bolts.

Torque - Front Axle Clamp Bolts: 20 N·m (2.0 kgf·m, 15 ft·lb)

NOTE

○

Tighten the two clamp bolts alternately two times to en-
sure even tightening torque.

•

Check the clearance [B] between the front axle collar [C]
and the right fork leg [D].

Standard Clearance:

ZX1200-B1/B2: 0.75

∼

3.3 mm (0.03

∼

0.13 in.)

ZX1200-B3

∼

: 0 mm (0 in.)

If the clearance is out of this range, remove the front wheel
again and check the axle, wheel hub and other related
parts for damage.

•

Next, tighten the left axle clamp bolts to the specified
torque.

Torque - Front Axle Clamp Bolts: 20 N·m (2.0 kgf·m, 15 ft·lb)

•

Install the front brake caliper (see Brakes chapter).

•

Check the front brake effectiveness.

WARNING

Do not attempt to ride the motorcycle until a full
brake lever is obtained by pumping the brake lever
until the pads are against the disc. The brakes will
not function on the first application of the lever if
this is not done.

Rear Wheel Removal

•

Raise the rear wheel off the ground with the stand [A].

10-6 WHEELS/TIRES

Wheels (Rims)

•

Remove:

Cotter Pin [A]
Axle Nut [B]
Axle [C]

•

Remove the chain [A] from the rear sprocket toward the
left.

•

Move the rear caliper back and remove the rear caliper
from the swingarm.

•

Remove the rear wheel.

CAUTION

Do not lay the wheel on the ground with the disc
facing down. This can damage or warp the disc.
Place blocks under the wheel so that the disc does
not touch the ground.

Rear Wheel Installation

•

Fit the collers on the both sides of the hub.

Right Side Coller [A]
Left Side Coller [B]

○

If the coupling is removed from the rear wheel, apply the
grease as shown.

Coupling [A]
Wheel Flange [B]
Apply Grease [C].

WHEELS/TIRES 10-7

Wheels (Rims)

•

Engage the drive chain with the rear sprocket.

•

Install the caliper bracket [A] onto the swingarm stop [B].

○

Install the axle from the right side of the wheel, and tighten
the axle nut.

Torque - Rear Axle Nut: 127 N·m (13 kgf·m, 94 ft·lb)

•

Insert a new cotter pin [A].

NOTE

○

When inserting the cotter pin, if the slots in the nut do
not align with the cotter pin hole in the axle, tighten the
nut clockwise [B] up to next alignment.

○

It should be within 30 degree.

○

Loosen once and tighten again when the slot goes past
the nearest hole.

•

Bend the cotter pin [A] over the nut [B].

•

Adjust the drive chain slack after installation (see Drive
Chain Slack Inspection in the Periodic Maintenance chap-
ter).

•

Check the rear brake effectiveness.

WARNING

Do not attempt to drive the motorcycle until a full
brake pedal is obtained by pumping the brake pedal
until the pads are against the disc. The brake will
not function on the first application of the pedal if
this is not done.

Kawasaki Ninja ZX-12R Motorcycle. Service Manual (2002-2005 year) - page 12