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Kawasaki KZ500 Manual Page 147

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is rotated, the pawls grasp the pegs and rotate
the shift drum. The overshift limiter hooks
keep the shift drum from moving more than
one gear at a time.
The 2 legs of the strong hairpin return spring
on the shift shaft rest against a stationary
centering pin. When the shift pedal is released,
the return spring brings the shift shaft back to
its center position.
1. Remove the engine sprocket cover as
described in this chapter.
2. Remove the engine sprocket as described in
this chapter.
3. Place a drain pan under the shift linkage
cover and remove the neutral indicator lead
(Figure 6 ) .
4. Remove the 7 screws (Figure l l ) , then
remove the shift linkage cover and gasket. Tap
the cover loose with a soft mallet, if necessary.
Use care; the cover is positioned with dowel
5. Note carefully how the shift link pawls
engage the shift drum. Move the shift linkage
arms out of engagement with the shift drum
(Figure 12) and pull the shift linkage out of the
Do not pull the shift fork rod (A, Figure
13) out. I f it is pulled out 2 in. (50 mm),
the shift forks within the crankcase will
fall off the rod. This would require
removal and disassembly of the engine
to reposition the forks.
6. To expose the pegs on the shifter drum,
remove the screw from the cover plate (B,
13) and remove the plate.
1. Inspect the seals in the shift linkage cover
(Figure 14). Replace any damaged seals; heat
the cover in an oven to about 2 12" F and tap the
old seals out. Install new seals flush with the
surface of the cover, with their numbered side
2. If the transmission fails to shift gears, check
for a weak pawl spring; bent, worn or binding
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