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:

Backups
The ECU takes the following measures to prevent engine damage when the DFI, ignition, S-KTRC or immobilizer system parts have troubles. Note: (1): D-J Method: When the engine load is light like at idling or low speed, the ECU determines the injection quantity by calculating fr ...

Air Switching Valve Removal
NOTICE Never drop the air switching valve especially on a hard surface. Such a shock to the air switching valve can damaged it. Remove the air cleaner housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter). Disconnect the connector [A]. Disconnect the hoses [B] from ...

Idle Speed Inspection
Start the engine and warm it up thoroughly. With the engine idling, turn the handlebar to both sides [A]. If handlebar movement changes the idle speed, the throttle cables may be improperly adjusted or incorrectly routed, or damaged. Be sure to correct any of these conditions before rid ...