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Crankcase; Splitting; Assembly - Kawasaki KDX200 Service Manual

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Crankcase
Splitting
Remove the engine
(see
Engine Removal/Installation chapter)
.
Set the engine on a
clean surface while
parts are being removed
.
Remove:
Magneto Cover
Output Shaft Sleeve and
O-ring
Right Engine Cover
Clutch
Primary Gear
Kickstarter Assembly
Kickstarter Idle Gear
Shift Drum Cam Bolt
Gear Set Lever
Magneto Flywheel and Stator
Cylinder Head
Cylinder
Piston
.
Remove the crankcase bolts
[A] .
CRANKSHAFT/
TRANSMISSION 7-7
Install the crankcase splitting tool
[A] and
bearing puller adapter [
8
]
into the left side of the crankcase. Be
certain
to screw the tool in all
the way.
Special Tool
-
Crankcase Splitting Tool
Assembly:
57001-1098
[AJ
Bearing Puller
Adapter:
57001
-136
[B]
.
Tighten the center bolt on the crankcase
splitting
tool to
split
the
crankcase halves.
Once the crankcase
is
split, remove the crankcase splitting tool, and lift
off the left crankcase half
.
Pull out the
shift
rods
[C]
.
Disengage the shift fork guide pins from the shift drum grooves
.
Take out the shift drum
[0] .
Remove the shift forks
[E]
from the transmission gears
.
Take
out
the drive shaft
[A]
and output shaft
[8]
together with their
gears meshed.
Remove the crankshaft from the right crankcase half using a press.
Assembly
.
Chip off the
old
gasket from the mating surfaces of the crankcase
halves, and clean off the
crankcase
with a high flash-point solvent.
After cleaning, apply transmission oil to the transmission gears, shift
drum, shift forks
and
so on.
Be sure to replace any oil seal removed with a new one. Press in the
new oil seal using a press and suitable tools so that the seal surface is
flush with the surface of the crankcase .
Apply high tempera ture grease to the oil seal lips.
Press in the ball bearings using the bearing
driver
sel until the bearing
bottoms out.

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   Also See for Kawasaki KDX200

This manual is also suitable for:

Kdx220 1995-2006

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