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:
Hub Bearing Installation
Before installing the hub bearings, blow any dirt or foreign
particles out of the hub with compressed air to prevent
contamination of the bearings.
Replace the bearings with new ones.
Install the bearings by using the bearing driver set which
does not contact the bearing inner race.
...
Special Tools and Sealant
Compression Gauge, 20 kgf/cm²:
57001-221
Valve Spring Compressor Assembly:
57001-241
Valve Spring Compressor Adapter,
25:
57001-1019
Valve Seat Cutter, 45° - 27.5:
57001-1114
Valve Seat Cutter, 45° - 32:
57001-1115
Valve Seat Cutter, 32° - 28:
57001-1119
Valve Seat Cutter ...
Air Intake Solenoid Valve Unit Test
Remove the air intake solenoid valve (see Air Intake Solenoid
Valve Removal in the Fuel System (DFI) chapter).
Set the hand tester [A] to the × 1 Ω range and connect it
to the air intake solenoid valve terminals as shown in the
figure.
Special Tool - Hand Tester: 57001-1394
...
Shift Pedal Removal
External Shift Mechanism Removal