Kawasaki Ninja Service Manual: Shift Fork/Gear Groove Wear Inspection

Kawasaki Ninja Service Manual / Crankshaft/Transmission / Transmission / Shift Fork/Gear Groove Wear Inspection

If the thickness of a shift fork ear is less than the service limit, the shift fork must be replaced.

Shift Fork Ear Thickness Standard: 5.7 6.0 mm (0.224
0.236 in.)
Service Limit: 5.6 mm (0.220 in.)

If the gear groove is worn over the service limit, the gear must be replaced.

Shift Fork/Gear Groove Wear Inspection


Gear Groove Width Standard: 6.05 6.15 mm (0.238
0.242 in.)


Service Limit: 6.25 mm (0.246 in.)

Shift Fork Bending Inspection
Visually inspect the shift forks, and replace any fork that is bent. A bent fork could cause difficulty in shifting, or allow the transmission to jump out of gear when under power. 90В° [A] ...

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 ...

Other materials:

Stick Coil Inspection
Remove the stick coils (see Stick Coil Removal). Measure the primary winding resistance [A] as follows. Connect the hand tester between the coil terminals. Set the tester to the × 1 Ω range, and read the tester. Measure the secondary winding resistance [B] as follows. Conn ...

ECU Communication Error (Service Code 39)
ECU Communication Line Inspection When the data is not sent from the ECU to the meter unit for more than about 10 seconds, the service code 39 is displayed. The data is sent through the CAN communication line. The service code 39 is detected with the meter unit. When the user mode, this commun ...

DFI Power Source
ECU Fuse Removal Refer to the 30 A Main/15 A ECU Fuse Removal in the Electrical System chapter. ECU Fuse Installation If a fuse fails during operation, inspect the DFI system to determine the cause, and then replace it with a new fuse of proper amperage. Refer to the Fuse Installation in ...