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:
Subthrottle Sensor Resistance Inspection
Turn the ignition switch to OFF.
Disconnect the subthrottle sensor connector.
Connect a digital meter [A] to the subthrottle sensor connector
[B].
Measure the subthrottle sensor resistance.
Subthrottle Sensor Resistance
Connections: BL lead [D] ←→ BR/BK lead [C]
Standard: ...
Tie-Rod Removal
Squeeze the brake lever slowly and hold it with a band
[A].
Remove the front footpeg bracket bolts [A].
Raise the rear wheel off the ground with the jack (see
Rear Shock Absorber Removal).
Special Tools - Jack: 57001-1238
Jack Attachment: 57001-1608
Remove:
Upper ...
General Lubrication
Lubricate the points shown below,
with either motor oil or regular grease,
in accordance with the Periodic Maintenance
Chart or whenever the vehicle
has been operated under wet or rainy
conditions.
Before lubricating each part, clean off
any rusty spots with rust remover and
wipe off any g ...