Kawasaki Ninja Service Manual: External Shift Mechanism Installation

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

External Shift Mechanism Installation


External Shift Mechanism Installation


External Shift Mechanism Installation


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

Turn the shift ratchet assembly while pushing the pawls.

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

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

External Shift Mechanism Installation


External Shift Mechanism Installation


External Shift Mechanism Installation


Special Tool - Outside Circlip Pliers: 57001-144

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

External Shift Mechanism Installation


External Shift Mechanism Removal
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 ...

External Shift Mechanism Inspection
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:

Oil Pump Removal
Remove: Coolant (Drain, see Coolant Change in the Periodic Maintenance chapter) Engine Oil (Drain, see Engine Oil Change in the Periodic Maintenance chapter) Sidestand Switch Lead Connector [A] (Disconnect) Bolt [B] and Water Pipe [C] Water Pump Cover Bolts [D] Water Pump Cover [E ...

Torque and Locking Agent
The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or silicone sealant etc. Letters used in the “Remarks” column mean: AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. G: Apply ...

Blank Key Detection (Service Code 36, Equipped Models)
Ignition Key Inspection Register the ignition key correctly (see Key Registration in the Electrical System chapter). If the service code 36 appears again, the transponder in the key is malfunction, replace it. Immobilizer System Circuit 1. ECU 2. Ignition Switch 3. Immobilizer Ampl ...