Kawasaki Ninja Service Manual: Shift Fork Guide Pin/Drum Groove Wear Inspection

Kawasaki Ninja Service Manual / Crankshaft/Transmission / Transmission / 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 replaced.

Shift Fork Guide Pin Diameter Standard: 6.9 7.0 mm (0.272
0.276 in.)
Service Limit: 6.8 mm (0.268 in.)

Shift Fork Guide Pin/Drum Groove Wear Inspection

If any shift drum groove is worn over the service limit, the drum must be replaced.

Shift Drum Groove Width Standard: 7.05 7.20 mm (0.278
0.283 in.)
Service Limit: 7.3 mm (0.287 in.)

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 re ...

Gear Dog and Gear Dog Hole Damage Inspection

Visually inspect the gear dogs [A] and gear dog holes [B]. Replace any damaged gears or gears with excessively worn dogs or dog holes. ...

Other materials:

Compression Damping Force Adjuster and Rebound Damping Force Adjuster Adjustment
The compression damping force adjuster and the rebound damping force adjuster are located on top of each front fork leg. Turn the adjuster clockwise with a screwdriver to increase damping force. Turn the adjuster counterclockwise to decrease damping force. NOTICE Do not force to t ...

Throttle Body Assy Disassembly
1. Throttle Body Assy 2. Subthrottle Valve Actuator 3. Idle Speed Control Valve Actuator 4. Main Throttle Sensor 5. Subthrottle Sensor 6. Primary Fuel Injectors 7. Delivery Pipe Assy NOTICE Do not remove, disassemble or adjust the main throttle sensor, subthrottle sensor, subthrottle v ...

Balancer Removal
Remove: Engine (see Engine Removal in the Engine Removal/Installation chapter) Oil Pan (see Oil Pan Removal in the Engine Lubrication System chapter) Remove: Balancer Shaft Clamp Lever Bolt [A] Balancer Shaft Clamp Bolt [B] Balancer Shaft Clamp Lever [C] Balancer Shaft [D] Bal ...