Kawasaki Ninja Service Manual: Shift Pedal Installation
- Install the rubber damper to the shift pedal.
Turn the chamfered side to inside.
- Assemble:
Shift Lever [A] and Locknut [B] (Left-hand Thread)
Shift Pedal [C] and Locknut [D]
Tie-Rod [E]
Turn the grooved end [F] of the tie-rod to the shift lever.
- Apply grease to the sliding surface [A] on the shift pedal
mounting bolt [B].
- Apply a non-permanent locking agent to the thread of the
shift pedal mounting bolt.
- Install:
Washer [C] (Inside Diameter: 8.2 mm, 0.32 in.)
Shift Pedal Assembly
Washer [D] (Frame No. JKAZXCJ1CA011772
Outside
Diameter: 16 mm, 0.63 in.)
Washer [E] (Frame No. JKAZXCJ1CA011772
Inside
Diameter: 18.3 mm, 0.72 in.)
- Tighten:
Torque - Shift Pedal Mounting Bolt: 25 N·m (2.5 kgf·m, 18
ft·lb)
- When installing the rubber damper [F], install it so that the
chamfered side [G] faces inward.
- Align the punch mark on the shift shaft with the slit [A] of
the shift lever.
- Tighten the shift lever bolt.
- After installation, the shift pedal lower surface [B] aligns
with the tie-rod lower surface [C].
If the pedal position is different, adjust it as follows.
- To adjust the pedal position, loosen the front locknut (left
-hand threads) and rear locknut, and then turn the tie-rod.
- Tighten the locknuts securely.
Remove:
Shift Lever Bolt [A]
Front Footpeg Bracket Bolts [B]
If the tie-rod [C] is to be removed from the shift pedal and
the shift lever, loosen the tie-rod locknuts [D].
The front tie-ro ...
Remove:
Shift Lever (see Shift Pedal Removal)
Oil Pump Drive Gear (see Oil Pump Drive Gear Removal/
Installation in the Engine Lubrication System
chapter)
Circlip [A]
Washer [B]
Spec ...
Other materials:
Transmission Assy Removal
Remove:
Engine Sprocket (see Engine Sprocket Removal in the
Final Drive chapter)
Gear Position Switch (see Gear Position Switch Removal
in the Electrical System chapter)
Collar [A]
O-ring [B]
Remove:
Clutch (see Clutch Removal in the Clutch chapter)
Shift Shaft Assembly ...
Air Cleaner Housing Removal
Remove the fuel tank (see Fuel Tank Removal).
Disconnect the secondary fuel hose [A] from the delivery
pipe of the nozzle assy [B] (see Fuel Hose Replacement
in the Periodic Maintenance chapter).
Disconnect the secondary fuel injector connectors [C].
Free the lead from the grooves [D].
...
Steering Damper Oil Leak Inspection
Visually inspect the steering damper [A] for oil leakage.
If the oil leakage is found on it, replace the steering
damper with a new one (see Steering Damper Removal/
Installation in the Steering chapter).
ZX1000JD/KD [B]
...
Shift Pedal Removal
External Shift Mechanism Removal