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:

Coolant Deterioration Inspection
Remove the right lower fairing (see Lower Fairing Removal in the Frame chapter). Visually inspect the coolant in the reserve tank [A]. If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If the coolant is brown, iron or steel parts are rusting. I ...

Coupling Bearing Inspection
Since the coupling bearing is made to extremely close tolerances, the clearance can not normally be measured. NOTE It is not necessary to remove the coupling bearing for inspection. If the bearing is removed, it will need to be replaced with a new one. Turn the bearing in the coupling b ...

Race Mode Display
This mode gives priority to reading the gear position rather than the speedometer reading. The gear position indicator can be displayed at the position of the speedometer on the normal mode. Also the speedometer is displayed instead of the clock on the normal mode. This mode can be used ...