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:
Rear Shock Absorber Installation
Replace the rear shock absorber nuts and tie-rod nuts
with new ones.
Tighten:
Torque - Rear Shock Absorber Nuts: 34 N·m (3.5 kgf·m, 25
ft·lb)
Tie-Rod Nuts: 34 N·m (3.5 kgf·m, 25 ft·lb)
When installing the rear shock absorber bracket [A], install
it so that the recess side [B] ...
Clutch Installation
Apply engine oil to the needle bearing [A] and the sleeve
[B].
Install:
Needle Bearing
Sleeve
Install the clutch housing [A].
Fit the holes [B] and projections [C].
Engage the clutch housing gear and the crankshaft primary
gear.
Install the spacer [A] and the clutch ...
Tail/Brake Light (LED) Removal/Installation
Remove:
Upper Seat Cover (see Seat Cover Removal in the
Frame chapter)
Disconnect the tail/brake light connector [A].
Remove:
Tail/Brake Light Mounting Screws [A]
Bolts [B] and Brackets [C]
Bolt [D]
Remove the tail/brake light [A].
Bring down the rear fender rea ...
Shift Pedal Removal
External Shift Mechanism Removal