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Gear Dog, Gear Dog Hole. And Dog Recess Damage - Kawasaki KDX200 Service Manual

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CRANKSHAFT/
TRANSMISSION 7-15
Gear Groove Width
Standard:
4.05 _
4.15 mm
Service Umlt:
4.3
mm
Shift
Fork Guide
Pin/Shift
Drum Groove Wear
.
Measure the diameter of each shilt fork guide pin [A]
,
and measure
the
width [B] of each shift drum groove.
*
If
the guide pin
on any shift fork is less
than
the service limit.
the fork
must be replaced
Shift
Fork
Guide
Pin
Dlameler
Standard:
5.975
-
5.994
mm
Service
limit
5.9
mm
*
If
any
shift drum groove is worn over the service
limit,
the
drum must
be
replaced.
Shift
Drum Groove Width
Standard:
6.05
-
6.20
mm
Service Limit
6.3 mm
Gear Dog, Gear Dog Hole, and Dog Recess Damage
.
Visually inspect the gear
dogs
[A], gear
dog holes
[B], and recesses
tel·
*
Replace
any
damaged
gears or
gears
with excessively
worn dogs
or
dog
holes
or dog
recesses.
Bal/Bearing Wear
Check the
ball
bearings
[AJ
in
the
crankcase.
O
Since
the ball
bearings are
made
to extremelv close
tolerances,
the
wear
must
be
Judged
bv feel rather
than
measurement.
Clean each
bearing in a high flash -point solvent,
dry
it (do not spin
the
bearing
while Lt is
dry)
,
and oil it with
transmission
oil.
.Turn
(AJ
each
bearing in
the
crankcase back and forth
[AJ
while
checking for
plav,
roughness, or
binding.
If bearing
plav, roughness,
or
binding
is
found,
replace
the bearing.

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   Also See for Kawasaki KDX200

This manual is also suitable for:

Kdx220 1995-2006

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