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:

Coupling Bearing Installation
Replace the bearing with a new one. Press in the bearing [A] until it is bottomed. Special Tool - Bearing Driver Set [B]: 57001-1129 Pack the bearing with high-temperature grease. Replace the circlip with a new one. Special Tool - Inside Circlip Pliers: 57001-143 Replace the grease se ...

Rider’s Seat Removal
Remove the bolts and seat cover. A. Bolts B. Seat Cover Remove the mounting bolts and pull off the seat upward. A. Mounting Bolts B. Rider’s Seat ...

Troubleshooting Guide
NOTE Refer to the Fuel System chapter for most of DFI trouble shooting guide. This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties. Engine Doe ...