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Removal; Installation; Inspection - Kawasaki KDX200 Service Manual

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5-16 CLUTCH
External Shift Mechanism
Removal
.Remove;
Shih Pedal
Magneto Cover
Right
Engine Cover
Clutch
Housing
Idle Gear
Pull out the
external
shift mechanism [A
J .
Remove the return spring
[C}
Remove the bolt and
take
off the gear sel lever
{ B] .
Check
that
the return spring pin [D
]
is not
loose.
Installation
eBefore
installing
the
shift shaft, apply high temperature grease to the
oil seal lips .
Torque the
gear
set lever bolt.
Torque
-
Gear Set lever
Bolt:
9.8 N·m (1 .0 kg-m,
87In-lb)
.lnstaU
the arm spring
[A]
as
shown
.
Inspection
Check
the
shift shaft
[
A] for bending and the serrations for
damage.
*
If
the shaft is bent. straighten or replace
it.
If
the S8fTations are
damaged,
replace
the
external shift mechanism
.
Check
the
return spring
[
8] and arm spring
[C]
for cracks or
distortion.
*
If
the springs are damaged in any
way,
replace
them.
eCheclc.
the shift mechanism arm
C O}
for distortion.
*
If
the shift mechanism arm is damaged in any
way,
replace
the
external
shift mechanism
.
Check
that the
shift shaft return spring pin
[Al
is not
loose.
*If
it is loose, unscrew
it,
apply a
non-
permanent locking agent to
the
threads,
8f1d torque
it.
Torque
-
Shift Shaft
Return
Spring Pin: 22 N-m (2.2 kg-m, 16.0 ft·lbl
.Check
the
gear
set lever and
its
spring for cracks or
distortion.
*
If the lever or spring is damaged in any
way,
replace
them.
Clutch
A
Side
~
A

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   Also See for Kawasaki KDX200

This manual is also suitable for:

Kdx220 1995-2006

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