Kawasaki Ninja Service Manual: Shift Fork/Gear Groove Wear Inspection

Kawasaki Ninja Service Manual / Crankshaft/Transmission / Transmission / Shift Fork/Gear Groove Wear Inspection

Measure the thickness of the shift fork ears [A], and measure 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: 5.7 6.0 mm (0.224
0.236 in.)
Service Limit: 5.6 mm (0.220 in.)

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

Shift Fork/Gear Groove Wear Inspection

Gear Groove Width Standard: 6.05 6.15 mm (0.238
0.242 in.)

Service Limit: 6.25 mm (0.246 in.)

Shift Fork Bending Inspection

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 Guide Pin/Drum Groove Wear Inspection

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 ...

Other materials:

Fuel Pressure Inspection
NOTE Be sure the battery is fully charged. Remove: Fuel Tank Covers (see Fuel Tank Removal) Fuel Tank Bolts (see Fuel Tank Removal) Primary Fuel Hose (see Fuel Hose Replacement in the Periodic Maintenance chapter) Be sure to place a piece of cloth around the fuel outlet pipe of the ...

Relay Circuit Inspection
Remove the relay box (see Relay Box Removal). Check conductivity of the following numbered terminals by connecting the hand tester and one 12 V battery to the relay box as shown in the figure (see Relay Box Internal Circuit in this section). If the tester does not read as specified, re ...

Bolts, Nuts and Fasteners Tightness Inspection
Check the tightness of the bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition. NOTE For the engine fasteners, check the tightness of them when the engine is cold (at room temperature). If there are loose fasteners, retighten them to ...