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Table H44
Clutch Housing, Drive
Shaft
Sleeve Diameter
Standard
Service Limit
Housing I.D.
30.020-30.041 mm
30.06
mm
Sleeve
O.D.
29.087-30.000 mm
29.07 mm
Clutch hub damage
Inspect where the teeth
on
the steel plates
wear
against the splines of
the
clutch hub.
If
there are
notches worn
into
the
splines,
replace the clutch
hub.
Clutch
release
mechanism wear
Visually
inspect
the
clutch
release
lever,
balls, and
ball ramp for damage
or
excessive
wear.
If
there
is
any damage or excessive wear, replace the clutch
release
lever,
balls, and ball ramp as a
set.
Lubrication
Lubricate the clutch release
lever,
balls, and ball ramp
with grease.
TRANSMISSION
Shift Mechanism
14'\
\
..
_/
1. Shift Arm
4.
Over
Shift Limi ter
2. Sh
ift
Drum
5. Return
Spring
Pin
3.
Shift
Drum Pin
6. Shift Shaft
MAINTENANCE-ENGINE 133
External shift mechanism inspection
Inspec
t
the
shift
arm, overshift
limi
ter,
arm spring,
and return spring.
Replace
any
broken or otherwise
damaged parts.
Measure
the free length
of the arm spring.
If it
is
longer than
the
servic limit,
replace
it
with
a new one.
Measure the
free length of the
shift positioner springs.
If
it is
longer
than
the
service limit, replace it
with
a
new one.
Table H45
Shift Arm Spring, Shift Positioner
Spring Free Length
Standard
Service Limit
Shift
Arm
18.0 mm
19mm
Positioner
22.5 mm
24mm
Check to
see
if
the
return
spring
pin
is
I
oose. If
it
is,
remove
it and apply a
non-permanent
locking
agent
to
the threads. Then
tighten it.
A. Return Spring Pin
Gear backlash
Spl
it
the
crankcase.
Leaving the drive
shaft and
output
shaft
assembly
in
place, measure
the
backlash
between gears 0
1
and
Dl,
02
and
D2, 03
and
D3,
04 and D4, 05
and 05,
06 and D6.
To measure the
backlash
,
set
a
dial
gauge against
the
teeth
on one
gear,
and move the gear
back and forth wh ile
holding
the
other
gear steady.
The
difference
between
the
highest
and the lowest
gauge
reading is
the
amount
of backlash.
Replace
both
gears
if
the amount of
backlash exceeds Lhe
serv
ice
limit.

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   Also See for Kawasaki Z250 1981

This manual is also suitable for:

Kz350 1981

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