Kawasaki Ninja Service Manual: Shift Pedal Installation

Kawasaki Ninja Service Manual / Crankshaft/Transmission / External Shift Mechanism / Shift Pedal Installation

Install the rubber damper to the shift pedal.

Turn the chamfered side to inside.

Assemble: Shift Lever [A] and Locknut [B] (Left-hand Thread) Shift Pedal [C] and Locknut [D] Tie-Rod [E]

Turn the grooved end [F] of the tie-rod to the shift lever.

Shift Pedal Installation

Apply grease to the sliding surface [A] on the shift pedal mounting bolt [B].
Apply a non-permanent locking agent to the thread of the shift pedal mounting bolt.
Install: Washer [C] (Inside Diameter: 8.2 mm, 0.32 in.) Shift Pedal Assembly Washer [D] (Frame No. JKAZXCJ1CA011772 Outside
Diameter: 16 mm, 0.63 in.) Washer [E] (Frame No. JKAZXCJ1CA011772 Inside
Diameter: 18.3 mm, 0.72 in.)

Shift Pedal Installation

Tighten: Torque - Shift Pedal Mounting Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb)
When installing the rubber damper [F], install it so that the chamfered side [G] faces inward.
Align the punch mark on the shift shaft with the slit [A] of the shift lever.
Tighten the shift lever bolt.
After installation, the shift pedal lower surface [B] aligns with the tie-rod lower surface [C].

If the pedal position is different, adjust it as follows.

To adjust the pedal position, loosen the front locknut (left -hand threads) and rear locknut, and then turn the tie-rod.
Tighten the locknuts securely.

Shift Pedal Installation

Shift Pedal Removal

Remove: Shift Lever Bolt [A] Front Footpeg Bracket Bolts [B] If the tie-rod [C] is to be removed from the shift pedal and the shift lever, loosen the tie-rod locknuts [D]. The front tie-ro ...

External Shift Mechanism Removal

Remove: Shift Lever (see Shift Pedal Removal) Oil Pump Drive Gear (see Oil Pump Drive Gear Removal/ Installation in the Engine Lubrication System chapter) Circlip [A] Washer [B] Spec ...

Other materials:

Drive Chain Removal/Installation
NOTE Since the drive chain is installed through the swingarm, The chain can not be removed other than by cutting it. Prepare the new link pin, link plate, grease seals, and tools for rejoining the chain. Remove: Bolts [A] Front Footpeg Bracket [B] Remove: Bolts [A] Chain Cover [B] ...

Air Cleaner
A clogged air cleaner restricts the engine’s air intake, increasing fuel consumption, reducing engine power, and causing spark plug fouling. This motorcycle’s air cleaner element consists of a wet paper filter, which cannot be cleaned. The air cleaner element must be replaced in acco ...

External Shift Mechanism Inspection
Examine the shift shaft [A] for any damage. If the shaft is bent, straighten or replace it. If the serration [B] are damaged, replace the shaft. If the spring [C] is damaged in any way, replace it. If the shift mechanism arm [D] is damaged in any way, replace the shaft. Check the s ...