Kawasaki Ninja Service Manual: Gear Dog and Gear Dog Hole Damage Inspection

Shift Fork Guide Pin/Drum Groove Wear Inspection

Measure the diameter of each shift fork guide pin [A], and measure the width [B] of each shift drum groove. If the guide pin on any shift fork is less than the service limit, the fork must be ...

External Shift Mechanism

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Other materials:

DFI System Troubleshooting Guide
NOTE This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties in DFI system. The ECU may be involved in the DFI electrical and ignition system tro ...

Spring Plate Free Play Measurement
Insufficient clutch free play will cause the engine braking effect to be more sudden, resulting in rear wheel hop. On the other hand, if the free play is excessive, the clutch lever may feel “spongy” or pulsate when pulled. Hold an extra drive shaft in a vise and install the following c ...

Cylinder Compression Measurement
NOTE Use the battery which is fully charged. Warm up the engine thoroughly. Stop the engine. Remove the spark plugs (see Spark Plug Replacement in the Periodic Maintenance chapter). Attach the compression gauge [A] and adapter [B] firmly into the spark plug hole. Using the startermo ...