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Kawasaki KZ1300-A1 Quick Reference Manual Page 84

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DISASSEMBLY--ENGINE INSTALLED
A. Shift Shaft
C. Overshift Limiter
B. Return Spring
D. Pin Holder
eUnscrew the bolt and put off the overshift limiter.
eUnscrew the bolt and remove the pin holder.
Installation Notes:
1. Match the positioning pin on the pin holder with the
hole in the shift drum, and the pin on the neutral
switch lever with the hole in the pin holder.
A. Align the pins with the holes.
2. Torque the pin holder bolts to 1.0 kg-m (87 in-Ibs),
and overshift limiter bolt to 2.5 kg-m (18.0 ft-Ibs).
3. Match the pin of overshift limiter with the notch of
sh ift I ever.
A. Pin Holder Bolt
C. Shift Lever
B. Overshift Limiter Bolt
D. Pin
4. If the return spring pin is loose, remove it.
Apply
a non-permanent locking agent to the threads, and
tighten it to 2.0 kg-m (1 4.5 ft-Ibs) of
torque.
OIL
PUMP
Removal:
eRemove the external shift mechanism cover (Pg. 82).
eUnscrew the pump mounting screws (2), and pull the
oil pump straight out.
A. Oil Pump
B.
Mounting Screws
Installation Note:
eBe sure to replace the oil pump gasket with a new
one.
Disassembly:
eRemove the oil pump cover screws
0
,
and the cover
CD.
eTake out the rotors
CD
.
ePull out the pin from the oil pump shah so that the
shaft press-fitted to the oil pump gear can be pulled
out.
Assembly Note:
e
After
assembling,
check the oil pump shaft to make
sure it rotates freely.
CLUTCH RELEASE
Removal:
eRemove the external shift mechanism cover (Pg. 82).
eRemove the
locknut,
washer, and release
lever.
eTake out the bolt and stop, and pull out the release.
Installation:
eMatching the positioning pin with the hole of the ex-
ternal shift mechanism cover, install the outer release
shaft to the
cover.
elnstall the steel ball assembly.
elnstall the inner release shaft using the oil seal guide
(special tool) to prevent the oil seal from being
dam-
aged.
84

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