Kawasaki Ninja Service Manual: External Shift Mechanism Inspection

Kawasaki Ninja Service Manual / Crankshaft/Transmission / External Shift Mechanism / External Shift Mechanism Inspection

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.

External Shift Mechanism Inspection


If the ratchet [A], pawls [B], pins [C] or springs [D] are damaged in any way, replace them.

External Shift Mechanism Inspection


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 Inspection


External Shift Mechanism Installation
Install the gear positioning lever [A] as shown in the figure. Install: Spring [B] Washer [C] Tighten: Torque - Gear Positioning Lever Bolt [D]: 12 N·m (1.2 kgf·m, 106 in·lb) ...

Wheels/Tires
...

Other materials:

Headlight Beam
NOTE Do not turn the bolts because the reflector in the headlight comes off. A. Bolts The left and right adjusters on the headlight can move the direction of the headlight beam to up, down, left and right by turning each adjuster itself as the below table. A. Left Adjuster ...

Camshaft Removal
Remove: Cylinder Head Cover (see Cylinder Head Cover Removal) Crankshaft Sensor Cover (see Crankshaft Sensor Removal in the Electrical System chapter) Using a wrench on the timing rotor bolt [A], turn the crankshaft clockwise until the line [B] (TDC mark for #1,4 pistons) on the timin ...

Alternator Cover Removal
Remove: Upper Fairing Assembly (see Upper Fairing Assembly Removal in the Frame chapter) Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) Bolt [A] Bring the heat insulator plate [B] forward to remove the alternator lead connector. Clear the p ...