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Gear Backlash; Shift Fork Bending; Shift Fork/gear Groove Wear - Kawasaki KZ400 Service Manual

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186 MAINTENANCE-ENGINE
Gear backlash
Split the crankcase.
Leaving the transmission in
place, measure the backlash between gears 0 1 and D l ,
0 2 and D2, 0 3 and D3, 0 4 and D4, 0 5 and D5, 0 6
and D6.
T o measure the backlash, set a dial gauge
against the teeth on one gear. Then move the gear back
and forth while holding the other gear steady.
The
difference between the highest and the lowest gauge
reading i s the amount o f backlash. Replace both gears
if the amount o f backlash exceeds the service limit.
A. Pawl Spring
C. Return Spring
B. Shift Pawls
Measure the free length o f the shift drum positioning
pin spring. I f
it
i s shorter than the service limit, replace
it
w i t h a new one.
A. Dial Gauge
B. Move
C. Hold
Table
H57
Gear Backlash
A. Positioning Pin
B. Pin Spring
Table H56
Positioning Pin Spring Length
I
Service L i m i t
1
30.7 m m
1
Check to see i f the return spring pin is loose. I f it
is, remove it and apply a non-permanent locking agent
t o the threads, and then screw
it
back in.
I
Service L i m i t
1
0.25 m m
I
Shift fork bending
Visually inspect the shift forks, and replace any fork
that is bent.
A bent f o r k could cause difficulty in
shifting or allow the transmission t o jump o u t o f gear
when under power.
Shift fork/gear groove wear
Measure the thickness o f the ears o f each shift fork,
and measure the width o f the shift f o r k grooves on gears
D314, 05, and 06. I f the thickness o f a shift fork ear is
under the service limit, the shift fork must be replaced.
I f a gear shift f o r k groove i s worn over the service limit,
the gear must be replaced.
A. Return Spring Pin
A. Gear 'Shift Fork Grooves
B. Shift Fork

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