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

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:

Fuel Hose Inspection (fuel leak, damage, installation condition)
If the motorcycle is not properly handled, the high pressure inside the fuel line can cause fuel to leak [A] or the hose to burst. Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) and check the fuel hoses. Replace the fuel hose if any fraying, cracks [B] or ...

Front Wheel Rotation Sensor Removal
NOTICE The wheel rotation sensor should be handled carefully, never struck sharply, as with a hammer, or allowed to fall on a hard surface since the wheel rotation sensor is precision made. Be careful not to get water or mud on the wheel rotation sensor. Do not try to disassemble or repair t ...

Engine Oil Change
Situate the motorcycle so that it is vertical after warming up the engine. Remove the engine oil drain bolt [A] to drain the oil. The oil in the oil filter can be drained by removing the filter (see Oil Filter Replacement). Replace the drain bolt gasket [B] with a new one. Tighten t ...