Kawasaki Ninja Service Manual: External Shift Mechanism Inspection

Kawasaki Ninja Service Manual / Crankshaft/Transmission / External Shift Mechanism / External Shift Mechanism Inspection

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.

External Shift Mechanism Inspection


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

External Shift Mechanism Inspection


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)

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

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

External Shift Mechanism Inspection


External Shift Mechanism Installation
Install the gear positioning lever [A] as shown in the figure. Install: Spring [B] Washer [C] Tighten: Torque - Gear Positioning Lever Bolt [D]: 12 N·m (1.2 kgf·m, 106 in·lb) ...

Wheels/Tires
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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] ...

Coolant Reserve Tank Installation
Install the following to the coolant reserve tank [A]. Pad [B] Gasket [C] Cap [D] Collar [E] Install the coolant reserve tank and tighten the bolt [F]. Run the hoses correctly (see Cable,Wire, and Hose Routing section in the Appendix chapter). Fill the coolant reserve tank with ...

Water Temperature Sensor Output Voltage Inspection
NOTE Be sure the battery is fully charged. Turn the ignition switch to OFF. Remove the throttle body assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter). Disconnect the water temperature sensor connector and connect the measuring adapter [A] between these connectors ...