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Kawasaki KZ1300-A1 Quick Reference Manual Page 107

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DISASSEMBLY -- ENGINE REMOVED
elnstall the 2nd gear with the dog recesses toward the
5th gear.
ePress fit the needle bearing inner race using the front
fork oil seal driver (special tool) until it stops at the
stepped portion.
A. Front Fork Oil Seal Driver (57001-191)
elnstall the needle bearing with the set ring groove
toward the 2nd gear.
elnstall the 4th gear on the opposite end of the needle
bearing, aligning its oil hole with the oil hole in the
shaft.
The groove for the shift fork faces toward the
3rd
gear.
elnstall the washer and 1 st gear in that order.
The
dog recesses face toward the 4th gear.
eFit the needle bearing into the outer shaft end.
Inner Shaft:
elnstall the ball bearing using the stem bearing driver
(special tool).
The set ring groove must be on the
bevel gear side.
A. Stem Bearing Driver (57001-137)
B. Groove
elnstall the set ring in the groove of the ball bearing.
The notched side of the set ring is on the bevel gear
side.
Set Ring
1.
1
st
Gear
3.
Set Ring
2.
Ball Bearing
4. Driven Shaft Bevel Gear
elnstall the shim(s), bevel
gear,
and iockwasher ("OUT
SIDE" marking faces out).
A.
·OUT SIDE"
Marking
eApply a non-permanent locking agent to the threads,
and screw the nut on the
inner
shaft.
NOTE: If bevel gear backlash and tooth contact pattern
is to be adjusted later, a non-permanent locking agent
is not needed, and torque the nut to more than 3.0
kg-m (22 ft-Ibs).
After the bevel gear adjustments are
completed, install the nut in the following manner:
eHolding the bevel gear with the special tool, tighten
the nut to 12.0 kg-m (87 ft-Ibs) of torque .
• Insert the inner shaft into the outer shaft from the
1 st gear
side.
ePut the needle thrust bearing and shim(s) on the inner
shaft
end.
Correct sequence starting with next to the
nut is the flat race (marked "WS"), caged needles, flat
107

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