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:

Passenger’s Seat Removal
Remove the passenger’s seat by inserting the ignition key into the seat lock, and turning it clockwise. A. Seat Lock B. Ignition Key C. Passenger’s seat D. Pull up NOTE When removing the passenger’s seat, pull it up while turning the key. ...

Crankshaft Side Clearance Inspection
Insert a thickness gauge [A] between the thrust washer [B] on the crankcase and the crank web [C] at the #3 main journal to determine clearance. If the clearance exceeds the service limit, replace the thrust washers as a set and check the width of the crankshaft #3 main journal. Cra ...

Radiator Cap Inspection
Remove: Radiator Cap (see Coolant Change in the Periodic Maintenance chapter) Check the condition of the bottom [A] and top [B] valve seals and valve spring [C]. If any one of them shows visible damage, replace the cap with a new one. Install the cap [A] on a cooling system pr ...