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:
External Shift Mechanism Inspection
Examine the shift shaft [A] for any damage.
If the shaft is bent, straighten or replace it.
If the serration [B] are damaged, replace the shaft.
If the spring [C] is damaged in any way, replace it.
If the shift mechanism arm [D] is damaged in any way,
replace the shaft.
Check the s ...
Turn Signal Relay Inspection
Remove the battery (see Battery Removal).
Take the turn signal relay [A] off the rear fender.
Disconnect the connector [B].
Connect one 12 V battery and turn signal lights as indicated
in the figure, and count how many times the lights
blink for one minute.
Turn Signal Relay ...
Exploded View
CL: Apply cable lubricant.
EO: Apply engine oil.
G: Apply grease.
HG: Apply high-temperature grease.
L: Apply a non-permanent locking agent.
M: Apply molybdenum disulfide grease.
R: Replacement Parts
S: Follow the specified tightening sequence.
Specifications
Special ...
Shift Pedal Removal
External Shift Mechanism Removal