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

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7-30 CRANKSHAFTrrRANSMISSION
Transmission
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
smoothly.
* If it does not turn smoothly, replace the washer with one
that is 0.5 mm (0.02
in.) thick.
NOTE
o
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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