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.
If the ratchet [A], pawls [B], pins [C] or springs [D] are damaged in any way, replace them.
If it is loose, unscrew it, apply a non-permanent locking agent to the threads, and tighten it.
Torque - Shift Shaft Return Spring Pin: 29 N·m (3.0 kgf·m, 21 ft·lb)
If the lever or spring are damaged in any way, replace them.
If they are badly worn or if they show any damage, replace it.
External Shift Mechanism Installation
Wheels/TiresIdle Speed
The idle speed inspection should be
performed in accordance with the Periodic
Maintenance Chart.
This motorcycle is equipped with the
Idle Speed Control valve. If the idle
speed is disturbed, inspection of the
idle speed control should be done by
an authorized Kawasaki dealer.
NOTE
While ...
Clutch
Clutch Operation Inspection
Pull the clutch lever just enough to take up the free play
[A].
Measure the gap between the lever and the lever holder.
If the gap is too wide, the clutch may not release fully. If
the gap is too narrow, the clutch may not engage fully. In
either case, adjust ...
Piston Ring Groove Width Inspection
Measure the piston ring groove width.
Use a vernier caliper at several points around the piston.
Piston Ring Groove Width
Standard:
Top [A] 0.82 0.84 mm (0.0323
0.0331 in.)
Second [B] 0.82 0.84 mm
(0.0323 0.0331 in.)
Service Limit:
0.92 mm (0.036 in.)
Second 0.92 mm (0.036 in.)
...