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Transmission; Shaft Assembly; Shift Drum And Fork Installation - Kawasaki KDX200 Service Manual

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CRANKSHAFT/
TRANSMISSION
7-1
3
Transm ission
Shah Removal
. Split
the crankcase (see Crankcase Splitting)
.
Pull out the shift rods
(A1,
and disengage the shift fork guide pins from
the shift drum
grooves.
Remove the shift drum
[8].
Remove the shift forks [C] from the transmission gears
.
Take out the drive shaft
[
0] and output shaft [E]
together,
with their
gears
meshed.
Shah Installation
Hold the drive shaft
[A]
and output shaft
[B] together,
with their gears
meshed,
and fit them into the right crankcase half.
Install the shift forks and shift drum (see Shift Drum and Fork
Instal
~
lation)
.
Shah Disassembly
Remove the circlips and disassemble the transmiSSion shaft.
Special Tool
-
Outside
Clrcilp
Pliers: 57001·144
Shaft Assembly
.
Apply transmission oil liberally to the transmission
shaft,
gears and
bearings.
Replace any circiips
[A]
that were removed with new
ones.
Special Tool
-
Outside
Clrcilp
Pliers:
57001-144
o
The drive shaft gears can be identified by size; the
smallest
diameter
gear is 1
Sl
gear, and the largest is 6th gear. Be sure that all parts are
pul back in the correct
sequence,
and facing the proper
direction,
and
that all circlips and the washer are properly in place.
1 st Gear [A
]
6th Gear (B]
3rd/
4th Gears
[
Cl
5th Gear
[ D)
2nd Gear [E)
OThe output shaft gears can be identified by size; the largest
diameter
gear is 1st
gear,
and the
smallest
is
6th
gear.
Be sure that ali parts are
put back in the correct sequence and facing the proper
direction,
and
that ali clrciips are properly in place.
O
Apply molybdenum disulfide grease to the Inside diameter of the 4th
gear [0].
2nd Gear [A]
5th Gear [8]
3rd Gear [C]
4th Gear [0]
6th Gear [
El
1st Gear
[F)
Check
that
each
gear
spins or slides freely on the transmission shaft
without binding after
assembly.

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   Also See for Kawasaki KDX200

This manual is also suitable for:

Kdx220 1995-2006

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