Kawasaki Ninja Service Manual: Damper Cam Inspection

Clutch Housing Spline Inspection

Visually inspect where the teeth [A] on the steel plates wear against the sub clutch hub splines [B]. If there are notches worn into the splines, replace the sub clutch hub. Also, replace the ...

Engine Lubrication System

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Other materials:

Cylinder Head Installation
NOTE The camshaft cap is machined with the cylinder head, so if a new cylinder head is installed, use the cap that is supplied with the new head. Install the dowel pins. Replace the cylinder head gasket with a new one. Replace the cylinder head bolt washers with new ones. Apply molybden ...

External Shift Mechanism Installation
Install the gear positioning lever [A] as shown in the figure. Install: Spring [B] Washer [C] Tighten: Torque - Gear Positioning Lever Bolt [D]: 12 N·m (1.2 kgf·m, 106 in·lb) Assemble: Ratchet [A] Pawls [B] Pins [C] Springs [D] Install the shift ratchet ...

Thermostat Installation
Replace the O-rings [A] with new ones, and apply grease to them. Assemble: O-rings Thermostat Housing [B] Thermostat [C] Thermostat Cap [D] Install the thermostat [A] in the housing so that the air bleeder hole [B] is on top. Tighten: Torque - Thermostat Cap Bolts: 5.9 N ...