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Transmission; Transmission Shaft; Transmission Shaft Assembly Notes - Kawasaki KX125 1990 Service Manual

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7-12 ENGINE BOTTOM ENO/TRANSMISSION
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Transmission
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Transmission Shaft Removal
-
Split the
crankcase (see Crankcase
Splitting),
.
Pull
out the shift
rod,
and
disengage the
shift
fork
guide
pins
from the shift
drum
grooves.
-
Remove
the shift
drum.
-
Remove the
shift forks
from the transmission
gears.
-
Take out the drive
shaft
and output shaft
together,
with their gears
meshed.
A.
Drive
Shaft
D.
Shift
Drum
B.
Output Shaft
E.
Shift Forks
C. Shift Rods
Transmission
Shaft Installation
Notes
-
Installation
is the
reverse
of remova
l.
-
Hold
the drive
shaft and
output
shaft
together, with
their
gears meshed, and
fit
them
into the
right
crankcase
half.
A.
Drive Shaft
B.
Output Shaft
-To
instal
l
the shift forks and shift drum,
see
the Shift
Drum and Fork Installation
Notes.
Transmission
Shaft
Disassembly Notes
-
Us ing circlip
pliers
(specia
l
tool:
57001-144)
to
re-
move the
circlips,
disassemble the transmission
shaft.
Transmission
Shaft
Assembly
Notes
-
Assembly is
the
reverse of
removal.
-
Apply transmission oil liberally to the transmission
shaft,
gears and
bearings.
-
Replace any
ci rclips
that were
removed with
new
ones.
oAlways install circlips
so
that the opening is aligned
with a spline
groove,
and install toothed washers so
that
the teeth are
not
aligned with the circlip open-
ing.
To install a circlip without
damage,
first fit the
circlip onto the shaft expanding it just enough to
install it, and
then
use a
suitable
gear to push the
circlip
into
place.
Clrclip
and
Toothed Washer Installation
1.
Teeth
of Toothed Washer
4.
Opening of Circlip
2.
Toothed
Washer
5.
Circlip
3. Groove of Shaft
6.
Shaft
-
The drive
shaft
gears
can
be
identified
by
size;
the
smallest
diameter
gear
is
1st
gear,
and
the
largest
is
5th (KX250) or
6th
(KX125).
Be
sure
that
a
ll
parts are
put
back in the
correct sequence,
facing the proper
direction,
and that all circlips
and
the washer are
properly
in
place.
Drive
Shaft Gears
KX125,
1.
1st
gear
(14T;
part of drive shaft)
2.
6th gear
(25T;
plain
side
faces right)
3.
3rd/4th gear (20T/22T; larger gear faces right)
4.
5th gear
(24T;
has an
identifyling
groove)
5.
2nd gear (14T; chamfered
side
faces
right)
5

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