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

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

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:

Stick Coil Input Voltage Inspection
NOTE Be sure the battery is fully charged. Turn the ignition switch to OFF. Remove the ECU (see ECU Removal in the Fuel System (DFI) chapter). Do not disconnect the ECU connectors. Connect a digital meter [A] to the connector [B] with the needle adapter set. Special Tool - N ...

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 circlips removed with new ones. Install the circlips [A] so that the opening [B] of it is aligned with ...

Idle Speed Control Valve Actuator Installation
Replace the O-ring [A] with a new one. Apply engine oil to the new O-ring. Install the idle speed control valve [A] as shown in the figure. 10° [B] Tighten: Torque - Idle Speed Control Valve Actuator Retainer Screws: 2.06 N·m (0.21 kgf·m, 18 in·lb) Install th ...