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:
Fuel Tank
The following octane rating gasoline
is recommended for the fuel tank.
Avoid filling the tank in the rain or where
heavy dust is blowing so that the fuel
does not get contaminated.
A. Tank Cap
B. Fuel Tank
C. Top Level
D. Filler Neck
WARNINGGasoline is extremely flammable
an ...
For Primary Fuel Injectors
Remove the air cleaner housing (see Air Cleaner Housing
Removal).
Disconnect the injector connector and connect the harness
adapter [A] between these connectors as shown in
the figure.
Main Harness [B]
Primary Fuel Injector #1 [C]
Special Tool - Measuring Adapter: 57001-1700
...
Drive Chain Removal/Installation
NOTE
Since the drive chain is installed through the swingarm,
The chain can not be removed other than by cutting it.
Prepare the new link pin, link plate, grease seals, and
tools for rejoining the chain.
Remove:
Bolts [A]
Front Footpeg Bracket [B]
Remove:
Bolts [A]
Chain Cover [B]
...