Kawasaki Ninja Service Manual: 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.
- 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.)
- 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.
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 ...
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:
ESD (Electronic Steering Damper) ECU Communication Error (Service Code 3C,
ZX1000JD/KD)
ESD ECU Communication Line Inspection
When the data (for status of ESD system) is not sent from
the ESD ECU to the meter unit and ECU, the service code
3C is displayed.
The data is sent through the CAN communication line.
The service code 3C is detected with the meter unit.
The FI symbol does ...
Exhaust Butterfly Valve Actuator Installation
Install the pulley [A] on the actuator so that the hole side
[B] align with the groove [C] on the shaft.
Make sure that the groove on the shaft is pointing toward
the center of the screw [D].
If the shaft position is incorrect, refer to the following
NOTE and procedures to electrically ad ...
Special Tools
Bearing Puller:
57001-135
Head Pipe Outer Race Press Shaft:
57001-1075
Steering Stem Nut Wrench:
57001-1100
Bearing Driver Set:
57001-1129
Steering Stem Bearing Driver, 42.5:
57001-1344
Steering Stem Bearing Driver Adapter,
41.5:
57001-1345
Head Pipe Outer Race Driver, 55:
57001- ...
Shift Pedal Removal
External Shift Mechanism Removal