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TRANSMISSION
145
-
Splined
washer
\
Grwve
Shaft
Inspection
1. Inspect the transmission shaft bearings or
bushings. Check for roughness, noise or
excessive play. To replace a bearing, use a gear
puller or heat the shaft in an oven to about 212"
F and tap the old bearing off.
2. Check each gear for missing teeth, chips and
excessive wear of the shift fork grooves. See
Table 1 for the maximum gear groove width
specification.
NOTE
When one gear is replaced, inspect the
mating gear on the opposite shaft very
closely. Any damage is likely to affect
both gears.
3. Check that the mating gear dogs and slots
(Figure 34) are in good condition. Worn dogs
and slots can cause the transmission to jump
out of gear.
4. Check that the gears slide smoothly on the
shaft splines.
Refer to Figure 32.
1. Note the following during gear set assembly:
a. Apply molybdenum disulfide grease to
any new parts. Oil all parts before
assembly.
b. Use new circlips when possible. Old clips
may have lost their tension during
removal.
c. When installing circlips on splined shafts,
position them so that their opening falls
on top of a spline groove and does not
align with a splined washer tooth (Figure
35).
2. The assembly sequence for the input shaft
(Figure 36) is 5th gear (flat side toward the
machined-in 1 st gear), washer, circlip, 3rd/4th
gear (3rd gear toward 5th gear), circlip, splined
washer, bushing (chamfered side toward
3rd/4th gear), 6th gear (dogs toward 4th gear),
splined washer, circlip, 2nd gear (recessed side
toward 6th gear), washer, needle bearing,
circlip, needle bearing outer race (with O-ring
inside).
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   Also See for Kawasaki KZ500

This manual is also suitable for:

Zx550Kz550Kzx550

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