Kawasaki Ninja Service Manual: Shift Pedal Installation

Kawasaki Ninja Service Manual / Crankshaft/Transmission / External Shift Mechanism / Shift Pedal Installation

Install the rubber damper to the shift pedal.

Turn the chamfered side to inside.

Assemble: Shift Lever [A] and Locknut [B] (Left-hand Thread) Shift Pedal [C] and Locknut [D] Tie-Rod [E]

Turn the grooved end [F] of the tie-rod to the shift lever.

Shift Pedal Installation

Apply grease to the sliding surface [A] on the shift pedal mounting bolt [B].
Apply a non-permanent locking agent to the thread of the shift pedal mounting bolt.
Install: Washer [C] (Inside Diameter: 8.2 mm, 0.32 in.) Shift Pedal Assembly Washer [D] (Frame No. JKAZXCJ1CA011772 Outside
Diameter: 16 mm, 0.63 in.) Washer [E] (Frame No. JKAZXCJ1CA011772 Inside
Diameter: 18.3 mm, 0.72 in.)

Shift Pedal Installation

Tighten: Torque - Shift Pedal Mounting Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb)
When installing the rubber damper [F], install it so that the chamfered side [G] faces inward.
Align the punch mark on the shift shaft with the slit [A] of the shift lever.
Tighten the shift lever bolt.
After installation, the shift pedal lower surface [B] aligns with the tie-rod lower surface [C].

If the pedal position is different, adjust it as follows.

To adjust the pedal position, loosen the front locknut (left -hand threads) and rear locknut, and then turn the tie-rod.
Tighten the locknuts securely.

Shift Pedal Installation

Shift Pedal Removal

Remove: Shift Lever Bolt [A] Front Footpeg Bracket Bolts [B] If the tie-rod [C] is to be removed from the shift pedal and the shift lever, loosen the tie-rod locknuts [D]. The front tie-ro ...

External Shift Mechanism Removal

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 ...

Other materials:

Inner Tube Inspection
Visually inspect the inner tube [A]. If there is any damage, replace the inner tube. Since damage to the inner tube damages the oil seal, replace the oil seal whenever the inner tube is replaced. NOTICE If the inner tube is badly bent or creased, replace it. Excessive bending, followed by ...

Ignition Switch Replacement
Remove: Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) Disconnect the lead connectors [A]. Remove: Steering Stem Head (see Stem, Stem Bearing Removal in the Steering chapter) Using a small chisel or punch [A], turn out the Torx bolts. ...

Hoses and Pipes
Hose Installation Install the hoses and pipes, being careful to follow bending direction. Avoid sharp bending, kinking, flattening or twisting. Run the hoses (see Cable, Wire, and Hose Routing section in the Appendix chapter). Install the clamp [A] as near as possible to the hose end ...