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Kawasaki KZ1300-A1 Quick Reference Manual Page 157

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OISASSEMBL Y -- CHASSIS
A. Pinion Joint Holder (57001-1050)
B. Spring Scale
A. Torque Wrench
elf the preload is out of the standard range, remove
the pinion gear nut and flat washer, replace the shim{s)
CD,
and re-check the preload.
Table G2
Preload
~
Standard
Measued with
Measued with
Spring Scale
Torque Wrench
When oil seal
0.45-0.70 kg
0.09 - 0.14 kg-m
is installed
(7.8-12.2 in-Ibs)
When oil seal
0.30-0.50 kg
0.06 - 0.1 0 kg-m
is removed
(5.2 - 8.7 in-Ibs)
NOTES: 1. For the spring scale method, when the shim
thickness is to be increased by 0.015 mm
,
the preload
will be decreased by about 0.1
kg,
and vice ve rsa.
For the torque wrench method
,
a 0.015 mm shim
increase decreases preload by 0 .02 kg-m (1.7 in-Ibs)
.
When the preload is out of the standard range, the
following formula can be used to estimate the most
desirable shim{s) thickness from
'
the present shim{s)
thickness
.
A
=
B
+
C{D - E)
A
Desirable Shim{s) Thickness (mm)
B
Present Shim{s) Thickness (mm)
C
0.15 mm/kg (when measured with the spring
scale),
or 0.75 mm
/
kg-m (when measured
with the torque wrench)
D
Preload when present shim{s) is installed
E
Standard Preload shown in Table G2
2.
Shims
CD
are available in the sizes shown in the
table.
Table G3
Shim Sizes
Thickness (mm)
Part Number
0.1
92025-1032
0.2
92025-1033
0.3
92025-1034
0.5
92025-1035
0.9
92025-1036
1.30
92025-1027
1.32
92025-1028
1.34
92025-1029
1.36
92025-1030
1.38
92025-1031
elnstall the flat washer and tighten the pinion gear nut
to 12.0 kg-m (87 ft-Ibs) of torque. Check the preload.
Repeat if necessary.
Backlash and Tooth Contact of Bevel Gears
Improper backlash and/or tooth contact of bevel
gears leads to noise and gear damage.
When replacing anyone of the following parts, make
sure to check and adjust backlash and tooth contact.
ORingGear (
@
on Fig. G103)
ORing Gear Ball Bearing (
@
on Fig. Gl03)
o
Final Gear Case Cover
(
CD
on
Fig.
G103)
o
Pinion Gear (@on Fig. Gl07)
oTapered Roller Bearing ( @on
Fig.
Gl 07)
OBearing Housing
((jJ)
on
Fig.
Gl 07)
oFinal Gear Case
(CD
on Fig. Gl15)
NOTE: After replacing anyone of the parts listed
above, install the 1.0 mm th ickness of a shim both
at the ring gear side and the pin ion
gear
side, wh ich
is the largest possible sh im
size.
The amount of backlash is influenced by the ring gear
position more than by the pinion
gear position.
Tooth
contact location is influenced by pinion gear position
more than by ring gear
position.
First change ring gear sh im (s)
CD
until the backlash
is
correct,
then adjust the tooth contact by changing
the pinion gear sh im (s)
CD
.
~ ~sh:
r::
:~a~.:;~!~:~n ::a;::r;~:p::s~
tooth contact. They must be replaced together.
Backlash Adjustment:
eClean any dirt and oil off the teeth of the bevel gears.
eAssemble the final gear case assembly (Pgs. 151-156),
and secure the pinion gear holder and spacers (special
tool) on the final gear case with the final gear case nuts
(4).
eTo measure the balcklash, secure a dial gauge on the
pinion gear holder (special tool). Set the needle against
the end of the rear hub coupling. Move the ring gear
back and forth while holding the pinion gear steady
.
The difference between the highest and the lowest
gauge reading is the amount of backlash.
157

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