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Kawasaki KZ1300-A1 Quick Reference Manual Page 195

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MAINTENANCE--ENGINE
coupled by the cam
damper.
The cam damper
includes
the cam follower
@,
damper cam
([j)
,
springs
@,
and
spring stop
CD
.
The cam follower is fixed on the outer
shaft, and rotates with the outer shaft and unable to
move sideways. The damper cam
is
serrated, and rotates
with the inner shaft but can slide sideways. When shocks
reach the cam damper, the cam follower turns relative to
the damper cam, absorbing the shocks.
Spiral
Bevel
Gears
The bevel gears are a spiral type, and carry higher
loads and run more quietly than straight bevel gears.
This is due to the following condition: before one tooth
rolls out of contact with
another,
a new tooth contact is
made. This distributes the torque load over several teeth,
as well as making for quiet operation. The bevel gears
are constructed as
pairs.
Thus, individual gears are not
interchangeable.
These gears must be replaced as a
matched set. Supporting shafts and bearings must be
rigid to maintain proper tooth contact.
If the correct alignment of the bevel gears
is
upset
by incorrect shim adjustment or damaged bearing{s},
the bevel gears become noisy and eventually break.
Transmission or external shift mechanism damage,
causing the transmission to misshift, overshift, and/or
jump out of gear, brings about more damage to the
transmission and also overrev damage to the engine
itself.
An improperly functioning transmission or ex·
ternal shift mechanism may be caused by the
following:
1. Loose
return
spring pin, and/or broken or weakened
return spring
2.
Broken or weakened shift drum positioning pin
spring
3. Broken or weakened shift pawl spring
4.
Damaged shift mechanism arm and/or overshift
limiter
5.
Loose shift drum bearing holder
6. Bent or worn shift fork{s}
7.
Worn shift fork grooves on gears
8. Worn shift fork guide pin{s}
9.
Worn shift drum groove{s}
10. Binding of shift drum positioning pin in the posi-
tioning
bolt.
11. Worn or damaged gear dogs, gear dog holes, and/or
gear dog recesses
12. Improperly functioning clutch or clutch release
13. Improper assembly or missing parts
Transmission noise results from the following:
1. Worn or damaged shafts, bearings, gear hubs or
teeth, etc.
2.
Worn or damaged damper cam, cam
follower,
or
serrated portions of the driven shaft
3. Improper backlash and/or tooth contact pattern of
bevel gears
External shift mechanism inspection
Inspect the shift pawls, overshift
limiter,
and return
spring.
Replace any broken or otherwise damaged parts.
A. Shift Pawl.
C. Return Spring
B.
Ovenhift Limiter
Measure the
free length
of
the
pawl spring. If
it is
longer
than the service
limit,
replace it
with
a new
one.
Measure the free
length
of the
shift
drum positioning
pin
spring.
If
it is
shorter
than
the
service limit, replace
it with
a
new one.
A. Pawl
Spring
B.
Position
ing Pin Spring
Table H64
Pawl Spring, Positioning Pin Spring
Free Length
Service Limit
Pawl Spring
18.9 mm
Positioning Pin Spring
49.4
mm
Shift fork bending
Visually inspect the
shift
forks, and replace
any fork
that is bent. A bent
fork could cause
difficulty
in shift-
ing or allow the transmission to
jump
out
of gear
when
under power.
Shift fork/gear groove wear
Measure the
thickness
of
the ears of each shift fork,
and measure
the
width of
the shift fork grooves on the
195

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