Kawasaki Ninja Service Manual: 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 assembly [A] to the holder [B] as
shown in the figure.
- Install the shift ratchet assembly to the shift drum cam [C].
Fit the pawls [D] and the grooves [E].
- Set the shift ratchet assembly [A] as shown in the figure.
Turn the shift ratchet assembly while pushing the pawls.
- Apply a non-permanent locking agent to the shift ratchet
assembly holder bolts [B].
- Tighten the shift ratchet assembly holder bolts temporarily.
Tighten the lower bolt first, and then tighten the upper one.
- Tighten:
Torque - Shift Ratchet Assembly Holder Bolts: 15 N·m (1.5
kgf·m, 11 ft·lb)
Tighten the lower bolt first, and then tighten the upper one.
- Replace the oil seal [A] with a new one.
- Apply grease to the lips of the grease seal.
- Apply engine oil to the needle bearing [B].
- Install:
Collar [A]
Washer [B]
Shift Shaft Assembly [C]
- Fit the hole [D] and the collar.
- Fit the return spring [E] and the pin [F].
- Replace the circlip [A] with a new one.
- Install:
Washer [B]
Circlip
Special Tool - Outside Circlip Pliers: 57001-144
Fit the circlip into the groove of the shift shaft securely.
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 ...
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, replac ...
Other materials:
Rear Wheel Rotation Sensor Signal (Service Code 24)
Rear Wheel Rotation Sensor Signal Inspection
The rear wheel rotation sensor sends the signal to the
ECU through the KIBS hydraulic unit (KIBS equipped
models). For other than KIBS equipped models, the
signal is sent directly to the ECU.
The ECU uses the rear wheel rotation sensor signal for
mo ...
Fuel Level Warning Indicator Light
: The fuel level warning
indicators
are activated when approximately 3.8 L
(1.0 US gal) of fuel remains as follows:
For models without KIBS:
A. Fuel Level Warning Indicator Light
B. “FUEL” Indication
The fuel level warning indicator light
( ) goes
on and “FUEL” blinks in the
...
Diode Circuit Inspection
Remove the relay box (see Relay Box Removal).
Check conductivity of the following pairs of terminals (see
Relay Box Internal Circuit in this section).
Diode Circuit Inspection
The resistance should be low in one direction and more
than 10 times as much in the other direction. If any dio ...