Kawasaki Ninja Service Manual: 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)

• Assemble: Ratchet [A] Pawls [B] Pins [C] Springs [D]

• Install the shift ratchet assembly [A] to the holder [B] as shown in the figure.
• Install the shift ratchet assembly to the shift drum cam [C].

Fit the pawls [D] and the grooves [E].

• Set the shift ratchet assembly [A] as shown in the figure.

Turn the shift ratchet assembly while pushing the pawls.

• Apply a non-permanent locking agent to the shift ratchet assembly holder bolts [B].
• Tighten the shift ratchet assembly holder bolts temporarily.

Tighten the lower bolt first, and then tighten the upper one.

• Tighten: Torque - Shift Ratchet Assembly Holder Bolts: 15 N·m (1.5 kgf·m, 11 ft·lb)

Tighten the lower bolt first, and then tighten the upper one.

• Replace the oil seal [A] with a new one.
• Apply grease to the lips of the grease seal.
• Apply engine oil to the needle bearing [B].

• Install: Collar [A] Washer [B] Shift Shaft Assembly [C]
• Fit the hole [D] and the collar.
• Fit the return spring [E] and the pin [F].

• Replace the circlip [A] with a new one.
• Install: Washer [B] Circlip

Special Tool - Outside Circlip Pliers: 57001-144

Fit the circlip into the groove of the shift shaft securely.