Kawasaki Ninja Service Manual: External Shift Mechanism Inspection

• Examine the shift shaft [A] for any damage.

If the shaft is bent, straighten or replace it.

If the serration [B] are damaged, replace the shaft.

If the spring [C] is damaged in any way, replace it.

If the shift mechanism arm [D] is damaged in any way, replace the shaft.

• Check the shift ratchet assembly for any damage.

If the ratchet [A], pawls [B], pins [C] or springs [D] are damaged in any way, replace them.

• 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: 29 N·m (3.0 kgf·m, 21 ft·lb)

• Check the gear positioning lever [B] and spring [C] for breaks or distortion.

If the lever or spring are damaged in any way, replace them.

• Visually inspect the shift drum cam [D].

If they are badly worn or if they show any damage, replace it.