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External Shift Mechanism Installation - Kawasaki ZR-7S Service Manual

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Remove the shift arm [A] and the overshift limiter [8] from
the shift drum pin, pull out the shift shaft [C], and remove
the external shift mechanism.
Do not pull the shift rod [D] out of crankcase, or
the shift forks inside the crankcase will fall to the
bottom of the oil pan, requiring removal of the
crankcase to install them.
Shift Mechanism
the shift drum pin has been removed, install it so that
the long pin [A] is positioned in the third hole clockwise
from the hole [8].
Olnstall the pin plate by inserting the long pin into the hole
[C] without the round edge.
OApply non-permanent locking agent to the threads of the
pin plate screw.
the tightening condition of the return spring pin
it if it is loose, apply non-permanent
agent to the threads, and tighten it.
Torque - Return Spring
Pin: 20 N.m (2.0 kgf.m, 14
Make sure that the return spring [A] and the ball spring [8]
are properly installed, and install the external shift mech-
OEngage the shift arm and the overshift limiter with the shift
drum pin.
. Apply silicon sealant [A] to the mating surfaces of the
crankcase and the external shift mechanism cover gas-
Sealant- Kawasaki B ond
(Silicon Sealant): 56019-120


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