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.
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 ...
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, replac ...
Other materials:
What Am I Responsible For?
You are responsible for maintaining your vehicle according to the maintenance
schedule shown in this owner’s manual.
You are responsible for notifying your dealer immediately if there is a problem,
and you, as the owner, will need to authorize the dealer to inspect the unit.
You will be re ...
Cam Wear Inspection
Remove the camshafts (see Camshaft Removal).
Measure the height [A] of each cam with a micrometer.
If the cams are worn down past the service limit, replace
the camshaft.
Cam Height
Standard:
Exhaust 35.043 35.157 mm
(1.3796 1.3841 in.)
Intake 38.243 38.357 mm
(1.5056 1.5101 in. ...
Inquiries to Rider
Each rider reacts to problems in different ways, so it is important to
confirm what kind of condition
the rider is dissatisfied with.
Try to find out exactly what problem occurs under exactly what
conditions by asking the rider; knowing
this information may help you reproduce the prob ...