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Shift Fork Bending Inspection; Shift Fork/gear Groove Wear Inspection; Shift Fork Guide Pin/shift Drum Groove Wear Inspection; Gear Damage Inspection - Kawasaki KX450F Service Manual

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9-26 CRANKSHAFT/TRANSMISSION
Transmission

Shift Fork Bending Inspection

Visually inspect the shift forks, and replace any fork that is
bent. A bent fork could cause difficulty in shifting, or allow
the transmission to jump out of gear when under power.
90° [A]

Shift Fork/Gear Groove Wear Inspection

Measure the thickness [A] of the shift fork ears, and mea-
sure the width [B] of the gear grooves (with which the fork
engages).
Shift Fork Ear Thickness
Standard:
Service Limit:
Gear Groove Width
Standard:
Service Limit:
If the thickness of a shift fork ear is less than the service
limit, the shift fork must be replaced.
If the gear groove is worn exceeding the service limit, the
gear must be replaced.
Shift Fork Guide Pin/Shift Drum Groove Wear
Inspection
Measure the diameter [A] of each shift fork guide pin, and
measure the width [B] of each shift drum groove.
Shift Fork Guide Pin Diameter
Standard:
Service Limit:
Shift Drum Groove Width
Standard:
Service Limit:
If the guide pin on any shift fork is less than the service
limit, the fork must be replaced.
If any shift drum groove is worn exceeding the service
limit, the drum must be replaced.

Gear Damage Inspection

Visually inspect the gear dogs [A] and gear dog holes [B].
Replace any damaged gears or gears with excessively
worn dogs or dog holes.
Visually inspect the gear teeth [C] on the transmission
gears.
The gear must be replaced if the teeth are badly dam-
aged.
When gear is repaired or replaced, the driving gear should
also be inspected and repaired or replaced if necessary.
4.9 ∼ 5.0 mm (0.193 ∼ 0.197 in.)
4.8 mm (0.189 in.)
5.05 ∼ 5.15 mm (0.199 ∼ 0.203 in.)
5.3 mm (0.209 in.)
5.9 ∼ 6.0 mm (0.232 ∼ 0.236 in.)
5.8 mm (0.228 in.)
6.05 ∼ 6.20 mm (0.238 ∼ 0.244 in.)
6.3 mm (0.248 in.)

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