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ENGINE
119
mallet-do not use a metal hammer or it
will damage the cases.
c. Carefully rotate the shift drum while
turning the output shaft. Check that all
gears engage smoothly and that each gear
position can be identified. You will have
to spin the output shaft quickly to keep
the "neutral finder" from locking you out
of 2nd and higher gears. Refer to Chapter
Six if the transmission does not work
correctly.
d. Remove the lower case half.
13. Make sure the crankcase mating surfaces
are completely clean and dry.
14. Apply a light coat of gasket sealer to the
sealing surfaces of the bottom case half. Cover
only flat surfaces, not curved bearing surfaces.
Make the coating as thin as possible.
CAUTION
Do not block any oil passage with
sealant.
15. Carefully place the lower case half in
position, fitting the shift forks in their proper
gear grooves.
16. Seat the upper case half onto the lower and
tap lightly with a plastic or rubber mallet-do
not use a metal hammer or it will damage the
cases.
17. Apply oil to the bolt threads and loosely
install the 17 lower crankcase bolts (Figure
146). Don't miss the bolt at the rear of the
engine.
NOTE
When installing crankcase bolts, check
that each one sticks up thesame amount
before you screw them all in. If not,
you've got a short bolt In a long hole and
vice versa.
18. Torque the 10 large bolts in 2 stages, as
specified in Table 2, following the sequence
numbers cast into the bottom of the engine
next to the bolts.
19. Torque the 7 smaller bolts as specified in
Table 2.
20. Rotate the crankshaft to make sure the
bearings are not too tight.
21. Carefully rotate the shift drum while
turning the output shaft. Check that all gears
engage smoothly and that each gear position
can be identified. You will have to spin the
output shaft quickly to keep the "neutral
finder" from locking you out of 2nd and higher
gears. Refer to Chapter Six if the transmission
does not work correctly.
22. Insert the secondary shaft through the
clutch side of the engine, through the thrust
washer (Figure 147) and into the starter clutch
assembly, aligning the shaft splines with the
secondary sprocket splines.
23. Before the secondary shaft is all the way in,
check that the 2 oil pump dowels are in place
(Figure 148) and hold the bearing retainer in
place (Figure 149).
24. Tap the secondary shaft into place with a
large socket placed over the secondary drive
gear until the clutch side bearing bottoms in the
crankcase.
25. Insert the alternator side bearing sleeve
(Figure 150).
NOTE
Before proceeding, inspect the primary
cham play as described in Crankcase
Separation in this chapter.
NOTE
Secondary shaft nut tightening will be
easier
if
you wait until the engine is
installed in the motorcycle.
26. Install the oil pump and oil pan; see
Oil
Pump Installation in this chapter.
27. Turn the engine over and install the 13
upper crankcase bolts (Figure 151). Torque
them as specified in Table 2.
28. Install the ignition advance assembly and
breaker point or pickup coil assembly as
described in Chapter Eight.
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   Also See for Kawasaki KZ500

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Zx550Kz550Kzx550

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