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Shift Fork Bending; Shift Fork Ear/gear Shift Fork Groove Wear; Shift Fork Guide Pin/shift Drum Groove Wear - Kawasaki ZR-7S Service Manual

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7-32 CRANKSHAFTITRANSMISSION
Transmission
.
Install the output shaft 2nd/3rd shift fork [A] and the 1st
shift fork [B]. These shift forks are identical parts.
OApply engine oil to the shift rod [C] and the ear of the fork.
Olnstall a new circlip on the shift rod and insert it from the
left of the case.
Special Tool
-
Outside Circlip Pliers: 57001-144
Olnstall the shift fork on the rod, starting with the shift fork
with the longer flange [D].
OPush the rod while engaging the guide pin [E] into the
groove of the shift drum.
Shift Fork Bending
. Visually inspect the shift forks, and replace any fork that is
bent. A bent fork could cause difficulty in shifting, or allow
the transmission to jump out of gear when under power.
[A] 90°
Shift Fork Ear/Gear Shift Fork Groove Wear
. Measure the thickness [A] of the shift fork ears, and mea-
sure the width [B] of the shift fork grooves on the trans-
mission gears.
* If the thickness of a shift fork ear is less than the service
limit, the shift fork must be replaced.
Shift Fork Ear Thickness
Standard:
4.9 - 5.0 mm (0.193 - 0.197 in.)
Service Limit: 4.8 mm (0.189
in.)
*
If a gear fork groove is worn over the service limit, the
gear must be replaced.
Gear Shift Fork Groove Width
Standard:
5.05- 5.15 mm (0.1988- 0.2028 in.)
Service Limit:
5.3 mm (0.2067
in.)
Shift Fork Guide Pin/Shift Drum Groove Wear
. Measure the diameter [A] of each shift fork guide pin, and
measure the width [B] of each shift drum groove.
* If the guide pin on any shift fork is less than the service
limit, the fork must be replaced.
Shift Fork Guide Pin Diameter
Standard:
Drive shaft
- 7.985 - 8.000
mm
(0.3144 - 0.3150 in.)
Output shaft
-
7.900- 8.000 mm
(0.3110 - 0.3150 in.)
Service Limit:
Drive shaft
-7.9
mm (0.311 in.)
Output shaft - 7.8 mm (0.307 in.)
GI13014551
C

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