Kawasaki Ninja Service Manual: Shift Fork Guide Pin/Drum Groove Wear Inspection

Kawasaki Ninja Service Manual / Crankshaft/Transmission / Transmission / 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 replaced.

Shift Fork Guide Pin Diameter Standard: 6.9 7.0 mm (0.272
0.276 in.)
Service Limit: 6.8 mm (0.268 in.)

Shift Fork Guide Pin/Drum Groove Wear Inspection

If any shift drum groove is worn over the service limit, the drum must be replaced.

Shift Drum Groove Width Standard: 7.05 7.20 mm (0.278
0.283 in.)
Service Limit: 7.3 mm (0.287 in.)

Shift Fork/Gear Groove Wear Inspection

Measure the thickness of the shift fork ears [A], and measure the width [B] of the gear grooves. If the thickness of a shift fork ear is less than the service limit, the shift fork must be re ...

Gear Dog and Gear Dog Hole Damage Inspection

Visually inspect the gear dogs [A] and gear dog holes [B]. Replace any damaged gears or gears with excessively worn dogs or dog holes. ...

Other materials:

Economical Riding Indicator
When the operator is driving the motorcycle for optimum fuel-efficiency, the economical riding indicator appears on the multifunction meter to indicate favorable fuel consumption. Monitoring the economical riding indicator can help the rider maximize fuel efficiency. A. Economical Riding ...

System Components
1. KIBS ECU With input from the front and rear wheel sensors and front caliper hydraulic pressure, the KIBS ECU analyzes various conditions on the motorcycle, and with additional information from the FI ECU (engine speed, throttle position, gear position, and clutch actuation) precisely control ...

Coupling Bearing Inspection
Since the coupling bearing is made to extremely close tolerances, the clearance can not normally be measured. NOTE It is not necessary to remove the coupling bearing for inspection. If the bearing is removed, it will need to be replaced with a new one. Turn the bearing in the coupling b ...