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

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

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. 90В° [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:

Radiator Hose and Pipe Inspection (coolant leak, damage, installation condition)
The high pressure inside the radiator hose can cause coolant to leak [A] or the hose to burst if the line is not properly maintained. Visually inspect the hoses for signs of deterioration. Squeeze the hoses. A hose should not be hard and brittle, nor should it be soft or swollen. Repl ...

Warning/Indicator Lights
: When the transmission is in neutral, the neutral indicator light goes on. : When the headlight is on high beam, the high beam indicator light goes on. : When the turn signal switch is pushed to the left or right, the turn signal indicator light blinks. ...

Swingarm Bearing Installation
Replace the needle bearings, ball bearing, grease seals and circlip with new ones. Install the needle bearings, ball bearing, grease seals and circlip as shown in the figure. Insert the needle bearing driver [A] into the needle bearing [B] and press the needle bearing into the housing u ...