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
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Other materials:

Battery Maintenance
It is the owner’s responsibility to keep the battery fully charged. Failure to do so can lead to battery failure and leave you stranded. If you are riding your vehicle infrequently, inspect the battery voltage weekly using a voltmeter. If it drops below 12.8 volts, the battery should be ...

Exhaust Butterfly Valve Cable Installation
Confirm whether pulley [A] is an angle shown in the figure. 41.7° ±7° [B] This position is original position of the pulley. NOTE Correct the position electrically after confirming the use is discontinued and there is no damage when differing from the angle of shown in the figure. ...

Radiator Inspection
Remove the radiator (see Radiator and Radiator Fan Removal). Check the radiator core. If there are obstructions to air flow, remove them. If the corrugated fins [A] are deformed, carefully straighten them. If the air passages of the radiator core are blocked more than 20% by unremovable ...