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Table of Contents
84 DISASSEMBLY-ENGINE REMOVED
•Remove the
screw,
and remove the
shift
positioner,
neutral
finder,
flat washer,
and
springs
(2).
A.
Shift Positioner
8. Neutral
Finder
C.
Spring
•Remove the screws (2)
and
flat washers (2).
Pull
out
the shift rods (2),
and
remove the
shift
forks (3).
•Remove
the
screws (2)
and shift
drum guide plate,
and
pul
l
out
the
shift
drum.
Installation:
•Blow the
oil passages
clean with compressed air.
•Apply a small amount
of molybdenum
disu
lfide
grease
to the shift drum
journal.
•Insert
the
shift drum
into
the
crankcase.
Turn
the
shift
drum so
that
the screw on the
shift
drum
contacts
the
neutral
indicator switch.
This makes
the neutral
finder
installation easier.
•Install the sh ift
drum guide plate and screws
(2)
.
•Position
the
3rd/4th
gear
shift
fork
so that the guide
pin on
the fork
is
aligned
with
the
groove
in
the
middle
of
the shift
drum.
Insert the shift rod through the
fork,
and
install the
flat
washer
and
screw.
(£67)
. .
A. Groove
C. 3rd/4th
Gear Shift
Fork
B. Guide Pin
•Install
the 5th
gear and
6th
gear shift
forks,
which
are
identical,
with their
guide
pins
aligned
with the remain-
ing grooves.
•Install the flat washer,
shift
pos1t1
oner,
and
neutral
finder using
the screw,
with the flat washer placed in
the
innermost
posit ion.
•Hook the
springs
(2)
in
the
lever holes so
that the
open-
ing
of the spring
end faces outwards
(Fig.
F66).
•Install the crankcase (Pg. 72).
•Install the engine.
Shift Drum
Disassembly:
•Remove the screw and shift
drum
pin
plate.
•Pul
l
out
the
pins (6}.
•Remove
the
screw which
is used to
contact
the
neutral
indicator
switch, if
damaged.
A.
Pin
8.
Shift Drum
Pin Plate
Drive
Shaft Disassembly:
•Remove the
needle
roller bearing outer race
;;:.
•Remove
the circlip
C
t,
and pul
l
off the
needle
roller
bearing@,
flat washer
,4
;,
and 2nd
gear:~)
.
•Remove the
circlip
(§;
, and
pull
off the
splined washer
(Z
)
,6thgear (t,
and splined washer.
•Remove
the circlip
@)
,
and pul
l
off the
3rd/4th
gear
ro.
•Remove
the circlip
@
, and
pul
l
off the flat
washer
1t
and
5th gear
' 1
J
.
•Pull off
the
ball bearing (2
}
using
the
bearing
puller
and adapter
(special
tools).
A. Bearing Puller (57001-135)
B. Adapter
(57001-166)

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Table of Contents

   Also See for Kawasaki Z250 1981

This manual is also suitable for:

Kz350 1981

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