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Output Shaft Gear Adjustment; Shift Fork And Shift Drum Removal - Kawasaki ZR-7S Service Manual

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Output Shaft Gear Adjustment
. Initially, install the standard 1 mm (0.04 in.) thick washer
[8] on the right of the 1st gear [A].
.Install the output shaft in the upper crankcase half.
OMake sure that the ball bearing and the needle bearing
are properly engaged in the set ring and the set pin.
Turn [C] the 1st gear by hand to check that it turns
* If it does not turn smoothly, replace the washer with one
that is 0.5 mm (0.02
in.) thick.
The adjustment washers are applicable for both shafts.
Shift Fork and Shift Drum Removal
. Disassemble the crankcase (see Crankcase Splitting).
Pull out the shift rod [A] from the lower crankcase half and
remove the two shift forks [8].
Remove the shift drum positioning bolt [A] and take out
the spring and the pin.
Flatten the lock washer and take out the shift drum guide
bolt [8].
Remove the cotter pin [C] and pull out the guide pin [0].
Remove the circlip and take out the shift drum cam [A].
Special Tool
Outside Circlip Pliers: 57001-144
Pull out the shift drum [8] and take out the 4th/5th shift
fork [C].


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