Kawasaki Ninja Service Manual: Shift Drum Disassembly

Transmission Shaft Assembly

Apply molybdenum disulfide oil solution to the sliding surfaces of the gears and shafts. Install the gears and the gear bushings [A] with their holes [B] aligned. Replace any circli ...

Shift Drum Assembly

Press and insert the ball bearing [A] on the shift drum [B] until it is bottomed. Install: Ball Bearing [C] Dowel Pin [D] and Shift Drum Cam [E] Align the pin with the groove in the shif ...

Other materials:

Cylinder Head Cover Installation
Replace the cylinder head cover gasket [A] with a new one Using a high flash-point solvent, clean off any oil or dirt that may be on the silicone sealant coating area. Dry them with a clean cloth. Apply silicone sealant [B] to the cylinder head as shown in the figure. Sealant - Li ...

Commutator Cleaning and Inspection
Clean the metallic debris off the between commutator segments [A]. NOTE Do not use emery or sand paper on the commutator. Check the commutator for damage or abnormal wear. Replace the starter motor with a new one if there is any damage or wear. Visually inspect the commutato ...

Valve-to-Guide Clearance Measurement (Wobble Method)
If a small bore gauge is not available, inspect the valve guide wear by measuring the valve to valve guide clearance with the wobble method as indicated below. Insert a new valve [A] into the guide [B] and set a dial gauge against the stem perpendicular to it as close as possible to the cy ...