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138
CHAPTER SIX
pawls; worn shift drum pins; a broken return
spring; or a broken return spring pin.
3 . If the t r a n s m i s s i o n u n d e r s h i f t s o r
overshifts, check for a binding, bent or worn
detent; a weak detent spring; bent or worn
pawls; worn shift drum pins; a loose return
spring pin; or a bent or weak return spring.
4. If the transmission jumps out ofgear, check
for a binding, bent or worn detent or a weak
detent spring.
5. Replace any other broken, bent, binding or
worn parts, including shift drum pins.
Installation
CA UTION
Use a locking agent such as Loctite Lock
N'Seal on all shift linkage screws. Loose
linkage will cause serious engine
damage.
1. Check that the shift drum ratchet pins are in
good condition. If the pins are removed, install
the long pin (which times the NEUTRAL light)
as shown in relation to the hole on the end of
the drum (Figure 15). Secure the pin plate
screw with a locking agent such as Loctite Lock
N' Seal.
2. Check that the shift shaft return spring pin is
tight (C, Figure 13). If loose, remove it, apply a
locking agent such as Loctite Lock N' Seal, and
tighten it securely.
3. Be sure the return spring and link springs are
in place on the shift linkage (Figure 16), then
spread the shift linkage pawls as you install the
linkage in the crankcase, mating the pawls to
the shift drum.
4. Make sure the return spring is positioned
correctly on the pin (A, Figure 17).
5. Check that the linkage cover dowel pins are
in place (B, Figure 17) and install the cover and
gasket. Install the 7 screws (Figure 11). The
middle front screw has a wiring clamp under it.
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   Also See for Kawasaki KZ500

This manual is also suitable for:

Zx550Kz550Kzx550

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