Kawasaki Ninja Service Manual: Shift Drum Disassembly

Kawasaki Ninja Service Manual / Crankshaft/Transmission / Transmission / Shift Drum Disassembly

Remove the shift drum (see Transmission Assy Disassembly).
While holding the shift drum with a vise, remove the shift drum cam holder bolt [A].
Remove: Shift Drum Cam [B] Dowel Pin [C] Ball Bearings [D] Shift Drum [E]

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:

Meter Unit Inspection
Remove the meter unit (see Meter Unit Removal). [1] Battery (+) [2] Fuel Reserve Switch [3] Ground (–) [4] Unused [5] Right Turn Signal Indicator Light (LED) (+) [6] Left Turn Signal Indicator Light (LED) (+) [7] High Beam Indicator Light (LED) (+) [8] Neutral Indicator Light (LED) (� ...

Oil Pump Installation
Install the outer rotor [A] into the crankcase. Assemble: Oil (Water) Pump Shaft [B] Pin [C] Inner Rotor [D] To prevent dropping, apply grease to the pin. Install the inner rotor assembly into the crankcase. Fit the slot [E] onto the projection [F]. Replace the O-ring [A ...

Precautions
1) No need of topping-up No topping-up is necessary in this battery until it ends its life under normal use. Forcibly prying off the seal cap to add water is very dangerous. Never do that. 2) Refreshing charge. Give refresh charge for 5 to 10 hours with charge current shown in the text (see ...