Kawasaki Ninja Service Manual: 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.
- 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.)
- 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.
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 ...
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:
Battery Removal
Remove the rider’s seat (see Seats
section in the GENERAL INFORMATION
chapter).
Turn the ignition switch to “OFF” and
disconnect the (–) cable from the battery.
Remove the red cap form the (+) terminal,
and disconnect the (+) cables
from the battery.
NOTE
The battery is ...
Caliper Fluid Seal Damage
The fluid seal (piston seal) [A] is placed around the piston
to maintain clearance between the pad and the disc. If
the seal is in a poor condition, it could lead the pad to wear
excessively or the brake to drag, which may cause the temperature
of the discs or the brake fluid to increase.
Re ...
Connecting Rod Installation
NOTICE
To minimize vibration, the connecting rods should
have the same weight mark.
Big End Cap [A]
Connecting Rod [B]
Weight Mark, Alphabet [C]
Diameter Mark [D] (“” or No Mark)
NOTICE
If the connecting rods, big end bearing inserts, or
crankshaft are replaced with new ones, select ...
Shift Pedal Removal
External Shift Mechanism Removal