Kawasaki Ninja Service Manual: Shift Fork Guide Pin/Drum Groove Wear Inspection

Kawasaki Ninja Service Manual / Crankshaft/Transmission / Transmission / 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 replaced.

Shift Fork Guide Pin Diameter Standard: 6.9 7.0 mm (0.272
0.276 in.)
Service Limit: 6.8 mm (0.268 in.)

Shift Fork Guide Pin/Drum Groove Wear Inspection

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.)

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 re ...

Gear Dog and Gear Dog Hole Damage Inspection

Visually inspect the gear dogs [A] and gear dog holes [B]. Replace any damaged gears or gears with excessively worn dogs or dog holes. ...

Other materials:

Precautions
1) No need of topping-up No topping-up is necessary in this battery until it ends its life under normal use. Forcibly prying off the seal cap to add water is very dangerous. Never do that. 2) Refreshing charge. Give refresh charge for 5 to 10 hours with charge current shown in the text (see ...

Alternator Rotor Removal
Remove the alternator cover (see Alternator Cover Removal). Clean off the oil from the outer circumference of the rotor. Hold the alternator rotor steady with the rotor holder [A] and suitable washer or plate [B]. Special Tools - Grip [C]: 57001-1591 Rotor Holder: 57001-1666 Flywheel P ...

Power Mode Indicator
This indicator shows the selected Power Mode. For more detailed information about the power mode, see power mode section in the How to Ride the Motorcycle chapter. A. Power Mode Indicator NOTE When all power mode indicators go off, the battery voltage is insufficient. Have the machine ...