Kawasaki Ninja Service Manual: Shift Fork/Gear Groove Wear Inspection

Kawasaki Ninja Service Manual / Crankshaft/Transmission / Transmission / Shift Fork/Gear Groove Wear Inspection

Measure the thickness of the shift fork ears [A], and measure the width [B] of the gear grooves.

If the thickness of a shift fork ear is less than the service limit, the shift fork must be replaced.

Shift Fork Ear Thickness Standard: 5.7 6.0 mm (0.224
0.236 in.)
Service Limit: 5.6 mm (0.220 in.)

If the gear groove is worn over the service limit, the gear must be replaced.

Shift Fork/Gear Groove Wear Inspection

Gear Groove Width Standard: 6.05 6.15 mm (0.238
0.242 in.)

Service Limit: 6.25 mm (0.246 in.)

Shift Fork Bending Inspection

Visually inspect the shift forks, and replace any fork that is bent. A bent fork could cause difficulty in shifting, or allow the transmission to jump out of gear when under power. 90° [A] ...

Shift Fork Guide Pin/Drum Groove Wear Inspection

Measure the diameter of each shift fork guide pin [A], and measure the width [B] of each shift drum groove. If the guide pin on any shift fork is less than the service limit, the fork must be ...

Other materials:

Chassis Parts Lubrication
Before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime. Lubricate the points listed below with indicated lubricant. NOTE Whenever the vehicle has been operated under wet or rainy conditions, or especially after using a high ...

Parts Location
1. Timing Rotor 2. Crankshaft Sensor 3. Horn 4. Oil Pressure Switch 5. Rear Brake Light Switch 6. Oxygen Sensor (Equipped Models) 7. Alternator 8. Stator Coil 9. Gear Position Switch 10. Sidestand Switch 11. Immobilizer Amplifier (Equipped Models) 12. Radiator Fan Motor 1 ...

Intake Air Temperature Sensor Output Voltage Inspection
NOTE Be sure the battery is fully charged. Turn the ignition switch to OFF. Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter). Disconnect the intake air temperature sensor connector and connect the measuring adapter [A] between these connectors as shown in ...