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Shift Drum And Fork Removal; Shift Drum And Fork Installation; Shift Drum Disassembly; Shift Drum Assembly - Kawasaki Z1000 Service Manual

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  • Contents

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9-30 CRANKSHAFT/TRANSMISSION
Transmission

Shift Drum and Fork Removal

•
Remove:
Lower Crankcase Half (see Crankcase Splitting)
Transmission Shafts
Gear Positioning Lever [A] (see External Shift Mecha-
nism Removal)
Bolt [B] and Screw [C]
Shift Drum Bearing Holder [D]
•
Pull out the shift rods [E], and take off the shift forks.
•
Pull out the shift drum [F].

Shift Drum and Fork Installation

•
Apply engine oil to the shift drum, forks and rods.
•
Install the shift rods [A], noting the groove position.
○
The rods are identical.
○
Position the one with shortest ears [B] on the drive shaft
and place the pin in the center groove in the shift drum
[C].
○
The two forks [D] on the output shaft are identical.
•
Install the forks so that its "266" and "267" side faces
clutch side.
•
Apply a non-permanent locking agent to the threads of
the shift drum bearing holder bolt and screw, and tighten
them.
Torque - Shift Drum Bearing Holder Bolt: 13 N·m (1.3 kgf·m,
115 in·lb)
Shift Drum Bearing Holder Screw: 5.9 N·m (0.60
kgf·m, 52 in·lb)

Shift Drum Disassembly

•
Remove the shift drum (see Shift Drum and Fork Re-
moval).
•
While holding the shift drum with a vise, remove the shift
drum cam holder bolt.
Shift Drum Cam Holder Bolt [A]
Dowel Pin [B]

Shift Drum Assembly

•
Be sure to install the dowel pin.
•
Apply a non-permanent locking agent to the threads of
the shift drum cam holder bolt, and tighten it.
Torque - Shift Drum Cam Holder Bolt: 12 N·m (1.2 kgf·m,
106 in·lb)

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