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Manuals
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Kawasaki Manuals
Motorcycle
VERSYS ABS
Service manual
Transmission; Transmission Assy Removal; Transmission Assy Installation - Kawasaki VERSYS ABS Service Manual
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Also See for VERSYS ABS
Owner's manual
-
176 pages
Owner's manual
-
173 pages
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Page
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631
Go
Page 1
Page 2
Page 3 - GENERAL INFORMATION
Page 4
Page 5
Page 6 - Country and area codes
Page 7 - Emission control information
Page 8 - How to use this manual
Page 9
Page 10
Page 11 - Table Of Contents
Page 12 - Before Servicing
Page 13
Page 14
Page 15
Page 16
Page 17 - Model Identification
Page 18
Page 19 - General Specifications
Page 20
Page 21
Page 22 - Unit Conversion Table
Page 23
Page 24
Page 25 - Periodic Maintenance Chart
Page 26 - Periodic maintenance
Page 27
Page 28 - Torque and Locking Agent
Page 29
Page 30
Page 31
Page 32
Page 33 - Specifications
Page 34
Page 35 - Special Tools
Page 36 - Periodic Maintenance Procedures
Page 37 - Throttle Control System Inspection
Page 38 - Engine Vacuum Synchronization Inspection
Page 39
Page 40 - Idle Speed Inspection
Page 41 - Idle Speed Adjustment
Page 42
Page 43 - Cooling System
Page 44 - Air Suction System
Page 45 - Valve Clearance Adjustment
Page 46
Page 47
Page 48
Page 49 - Clutch
Page 50 - Wheel/Tire Damage Inspection
Page 51 - Wheel Bearing Damage Inspection
Page 52 - Drive Chain Slack Inspection
Page 53 - Wheel Alignment Inspection
Page 54 - Drive Chain Wear Inspection
Page 55 - Brake System
Page 56 - Brake Operation Inspection
Page 57 - Brake Pad Wear Inspection
Page 58 - Suspensions
Page 59 - Steering System
Page 60 - Steering Stem Bearing Lubrication
Page 61 - Electrical System
Page 62
Page 63 - Headlight Aiming Inspection
Page 64 - Sidestand Switch Operation Inspection
Page 65 - Engine Stop Switch Operation Inspection
Page 66 - Others
Page 67 - Bolts, Nuts and Fasteners Tightness Insp...
Page 68 - Replacement Parts
Page 69 - Vehicle-down Sensor Mounting Dampers Rep...
Page 70
Page 71
Page 72 - Radiator Hose and O-ring Replacement
Page 73 - Oil Filter Replacement
Page 74 - Brake Hose Replacement
Page 75 - Brake Fluid Change
Page 76
Page 77 - Master Cylinder Rubber Parts Replacement
Page 78 - Caliper Rubber Parts Replacement
Page 79
Page 80 - Spark Plug Replacement
Page 81
Page 82
Page 83
Page 84
Page 85
Page 86 - Exploded View
Page 87
Page 88
Page 89
Page 90
Page 91
Page 92 - DFI System
Page 93
Page 94
Page 95
Page 96
Page 97 - DFI Parts Location
Page 98 - Specifications
Page 99
Page 100 - Special Tools and Sealant
Page 101
Page 102 - DFI Servicing Precautions
Page 103 - DFI Servicing Precautions
Page 104 - Troubleshooting the DFI System
Page 105
Page 106
Page 107 - Inquiries to Rider
Page 108
Page 109
Page 110 - DFI System Troubleshooting Guide
Page 111
Page 112
Page 113
Page 114
Page 115 - Self-Diagnosis
Page 116 - Service Code Clearing Procedures
Page 117
Page 118 - How to Read Service Codes
Page 119 - Service Code Table
Page 120 - Backups
Page 121
Page 122 - Main Throttle Sensor (Service Code 11)
Page 123 - Main Throttle Sensor Output Voltage Insp...
Page 124 - Main Throttle Sensor Resistance Inspecti...
Page 125
Page 126 - Intake Air Pressure Sensor (Service Code...
Page 127 - Intake Air Pressure Sensor Output Voltag...
Page 128
Page 129
Page 130
Page 131
Page 132 - Intake Air Temperature Sensor (Service C...
Page 133 - Intake Air Temperature Sensor Resistance...
Page 134 - Water Temperature Sensor (Service Code 1...
Page 135 - Water Temperature Sensor Resistance Insp...
Page 136 - Crankshaft Sensor (Service Code 21)
Page 137 - Speed Sensor (Service Code 24, 25)
Page 138 - Speed Sensor Output Voltage Inspection
Page 139
Page 140 - Vehicle-down Sensor (Service Code 31)
Page 141
Page 142
Page 143 - Subthrottle Sensor (Service Code 32)
Page 144 - Subthrottle Sensor Output Voltage Inspec...
Page 145 - Subthrottle Sensor Resistance Inspection
Page 146
Page 147 - Oxygen Sensor-not activated (Service Cod...
Page 148
Page 149 - Stick Coils #1, #2: (Service Code 51, 52...
Page 150
Page 151 - Radiator Fan Relay (Service Code 56)
Page 152
Page 153 - Subthrottle Valve Actuator (Service Code...
Page 154 - Subthrottle Valve Actuator Input Voltage...
Page 155 - Air Switching Valve (Service Code 64)
Page 156 - Oxygen Sensor Heater (Service Code 67) (...
Page 157
Page 158
Page 159 - Oxygen Sensor-Incorrect Output Voltage (...
Page 160
Page 161 - FI Indicator Light (LED)
Page 162 - FI Indicator Light (LED) Inspection
Page 163 - ECU
Page 164 - ECU Power Supply Inspection
Page 165
Page 166 - Fuel Line
Page 167 - Fuel Flow Rate Inspection
Page 168
Page 169 - Fuel Pump
Page 170 - Fuel Pump Operation Inspection
Page 171 - Pressure Regulator Removal
Page 172
Page 173 - Fuel Injectors
Page 174 - Fuel Injector Output Voltage Inspection
Page 175 - Injector Signal Test
Page 176 - Injector Unit Test
Page 177
Page 178
Page 179 - Throttle Grip and Cables
Page 180 - Throttle Body Assy
Page 181 - Throttle Body Assy Installation
Page 182 - Throttle Body Assy Disassembly
Page 183 - Throttle Body Assy Assembly
Page 184 - Air Cleaner
Page 185 - Air Cleaner Housing Installation
Page 186 - Fuel Tank
Page 187
Page 188 - Fuel Tank Installation
Page 189 - Fuel Tank and Cap Inspection
Page 190 - Evaporative Emission Control System (CAL...
Page 191 - Separator Inspection
Page 192
Page 193
Page 194 - Exploded View
Page 195 - Cooling system
Page 196 - Coolant Flow Chart
Page 197
Page 198 - Specifications
Page 199 - Special Tools
Page 200 - Coolant
Page 201 - Cooling System Flushing
Page 202 - Water Pump
Page 203 - Water Pump Inspection
Page 204 - Water Pump Housing Disassembly
Page 205 - Radiator
Page 206 - Radiator and Radiator Fan Installation
Page 207 - Radiator Inspection
Page 208 - Radiator Filler Neck Inspection
Page 209 - Thermostat
Page 210 - Thermostat Inspection
Page 211 - Hose and Pipes
Page 212 - Water Temperature Sensor
Page 213
Page 214
Page 215 - Exploded View
Page 216
Page 217
Page 218
Page 219
Page 220 - Exhaust System Identification
Page 221 - Specifications
Page 222
Page 223 - Special Tools and Sealant
Page 224
Page 225 - Clean Air System
Page 226 - Air Suction Valve Inspection
Page 227 - Air Switching Valve Unit Test
Page 228 - Cylinder Head Cover
Page 229 - Cylinder Head Cover Installation
Page 230
Page 231 - Camshaft Chain Tensioner
Page 232 - Camshaft Chain Tensioner Installation
Page 233 - Camshaft, Camshaft Chain
Page 234
Page 235 - Camshaft Installation
Page 236
Page 237
Page 238 - Camshaft, Camshaft Cap Wear
Page 239 - Camshaft Chain Removal
Page 240 - Cylinder Head
Page 241 - Cylinder Head Removal
Page 242 - Cylinder Head Installation
Page 243 - Cylinder Head Warp
Page 244 - Valves
Page 245 - Valve Guide Installation
Page 246 - Valve Seat Inspection
Page 247
Page 248
Page 249
Page 250
Page 251 - Cylinder, Pistons
Page 252 - Piston Installation
Page 253 - Cylinder Wear
Page 254 - Piston Ring, Piston Ring Groove Wear
Page 255 - Piston Ring End Gap
Page 256 - Throttle Body Assy Holder
Page 257 - Muffler
Page 258 - Muffler Body and Exhaust Pipe Installati...
Page 259
Page 260 - Exploded View
Page 261
Page 262 - Specifications
Page 263 - Special Tool and Sealant
Page 264 - Clutch Lever and Cable
Page 265 - Clutch Lever Installation
Page 266 - Clutch Cover
Page 267 - Clutch Cover Disassembly
Page 268 - Clutch Removal
Page 269 - Clutch Installation
Page 270
Page 271 - Clutch Plate, Wear, Damage Inspection
Page 272 - Clutch Housing Finger Inspection
Page 273
Page 274 - Exploded View
Page 275 - Engine lubrication system
Page 276 - Engine Oil Flow Chart
Page 277
Page 278 - Specifications
Page 279 - Special Tools and Sealant
Page 280 - Engine Oil and Oil Filter
Page 281 - Oil Pan
Page 282 - Oil Pan Installation
Page 283 - Oil Pressure Relief Valve
Page 284 - Oil Pump
Page 285 - Oil Pump Installation
Page 286
Page 287 - Oil Pressure Measurement
Page 288 - Oil Pressure Switch
Page 289
Page 290 - Exploded View
Page 291
Page 292 - Engine Removal/Installation
Page 293
Page 294 - Engine Installation
Page 295
Page 296
Page 297
Page 298 - Exploded View
Page 299
Page 300
Page 301
Page 302 - Specifications
Page 303
Page 304
Page 305 - Special Tools and Sealants
Page 306 - Crankcase Splitting
Page 307 - Crankcase Splitting
Page 308 - Crankcase Assembly
Page 309
Page 310
Page 311
Page 312
Page 313
Page 314 - Crankshaft and Connecting Rods
Page 315 - Connecting Rod Installation
Page 316
Page 317
Page 318 - Crankshaft/Connecting Rod Cleaning
Page 319 - Connecting Rod Twist
Page 320
Page 321 - Crankshaft Runout
Page 322 - Crankshaft Main Bearing Insert/Journal W...
Page 323
Page 324 - Balancer
Page 325
Page 326
Page 327 - External Shift Mechanism
Page 328 - External Shift Mechanism Removal
Page 329 - External Shift Mechanism Installation
Page 330 - External Shift Mechanism Inspection
Page 331 - Transmission
Page 332 - Transmission Assy Disassembly
Page 333 - Transmission Assy Assembly
Page 334 - Transmission Shaft Removal
Page 335 - Transmission Shaft Disassembly
Page 336
Page 337
Page 338 - Shift Drum and Fork Removal
Page 339 - Gear Dog and Gear Dog Hole Damage
Page 340 - Ball Bearing, Needle Bearing, and Oil Se...
Page 341
Page 342 - Exploded View
Page 343
Page 344 - Specifications
Page 345 - Special Tools
Page 346 - Wheels (Rims)
Page 347
Page 348 - Rear Wheel Removal
Page 349 - Rear Wheel Installation
Page 350 - Wheel Inspection
Page 351 - Axle Inspection
Page 352 - Balance Weight Installation
Page 353 - Tires
Page 354
Page 355 - Tire Repair
Page 356 - Hub Bearing
Page 357 - Hub Bearing Lubrication
Page 358
Page 359
Page 360 - Exploded View
Page 361 - Final drive
Page 362 - Specifications
Page 363 - Special Tools
Page 364 - Drive Chain
Page 365 - Drive Chain Installation (KLE650CAF/DAF)
Page 366
Page 367 - Drive Chain Removal (KLE650CBF/DBF)
Page 368 - Drive Chain Installation (KLE650CBF/DBF)
Page 369
Page 370
Page 371 - Sprocket, Coupling
Page 372 - Engine Sprocket Installation
Page 373 - Coupling Installation
Page 374 - Coupling Bearing Inspection
Page 375 - Rear Sprocket Warp Inspection
Page 376
Page 377
Page 378
Page 379 - Exploded View
Page 380
Page 381
Page 382
Page 383
Page 384
Page 385
Page 386
Page 387
Page 388 - Specifications
Page 389
Page 390 - Brake Lever Position Adjustment
Page 391 - Brake Pedal Removal
Page 392
Page 393 - Calipers
Page 394 - Caliper Installation
Page 395 - Caliper Fluid Seal Damage
Page 396 - Rear Caliper Holder Shaft Wear
Page 397 - Brake Pads
Page 398 - Master Cylinder
Page 399 - Rear Master Cylinder Removal
Page 400 - Front Master Cylinder Disassembly
Page 401 - Brake Disc
Page 402 - Brake Fluid
Page 403
Page 404
Page 405 - Brake Hose
Page 406 - Anti-Lock Brake System (Equipped Models)
Page 407
Page 408
Page 409 - ABS Servicing Precautions
Page 410
Page 411 - ABS Troubleshooting Outline
Page 412
Page 413
Page 414 - Inquiries to Rider
Page 415
Page 416 - Self-diagnosis Outline
Page 417 - Service Code Clearing Procedures
Page 418
Page 419 - How to Read Service Codes
Page 420
Page 421 - ABS Indicator Light (LED) Inspection
Page 422 - Solenoid Valve Inspection (Service Code ...
Page 423
Page 424 - Front, Rear Wheel Rotation Difference Ab...
Page 425 - Front Wheel Rotation Sensor Signal Abnor...
Page 426 - Front Wheel Rotation Sensor Wiring Inspe...
Page 427 - Rear Wheel Rotation Sensor Signal Abnorm...
Page 428 - Rear Wheel Rotation Sensor Wiring Inspec...
Page 429 - Power Supply Voltage Abnormal (Over-Volt...
Page 430 - ECU Inspection (Service Code 55)
Page 431
Page 432 - ABS Hydraulic Unit Installation
Page 433 - Front Wheel Rotation Sensor Removal
Page 434 - Rear Wheel Rotation Sensor Installation
Page 435 - Wheel Rotation Sensor Inspection
Page 436 - 25 A ABS Solenoid Valve Relay Fuse Remov...
Page 437 - Fuse Inspection
Page 438
Page 439
Page 440 - Exploded View
Page 441
Page 442
Page 443
Page 444 - Specifications
Page 445 - Special Tools
Page 446
Page 447 - Front Fork
Page 448 - Front Fork Removal (Each Fork Leg)
Page 449 - Fork Oil Change
Page 450
Page 451
Page 452
Page 453 - Front Fork Disassembly
Page 454 - Front Fork Assembly
Page 455 - Inner Tube, Outer Tube Inspection
Page 456 - Dust Seal Inspection
Page 457 - Rear Shock Absorber
Page 458 - Rear Shock Absorber Removal
Page 459 - Rear Shock Absorber Inspection
Page 460 - Swingarm
Page 461 - Swingarm Bearing Removal
Page 462 - Swingarm Bearing, Sleeve Inspection
Page 463 - Swingarm Bearing Lubrication
Page 464
Page 465
Page 466 - Exploded View
Page 467
Page 468 - Special Tools
Page 469 - Steering Inspection
Page 470 - Steering Stem
Page 471 - Stem, Stem Bearing Installation
Page 472
Page 473 - Stem Bearing Lubrication
Page 474 - Stem Cap Deterioration, Damage
Page 475 - Handlebar
Page 476
Page 477
Page 478 - Exploded View
Page 479
Page 480
Page 481
Page 482
Page 483
Page 484 - Seat
Page 485 - Fairings
Page 486 - Middle Fairing Installation
Page 487 - Upper Fairing Bracket Removal
Page 488 - Side Covers
Page 489 - Seat Covers
Page 490 - Fenders
Page 491 - Rear Fender Front Removal
Page 492 - Frame Inspection
Page 493 - Windshield
Page 494 - Windshield Removal
Page 495 - Sidestand
Page 496 - Frame Cover
Page 497 - Rear View Mirrors
Page 498
Page 499
Page 500
Page 501 - Exploded View
Page 502
Page 503
Page 504
Page 505
Page 506
Page 507
Page 508 - Specifications
Page 509 - Special Tools and Sealant
Page 510 - Parts Location
Page 511
Page 512 - Wiring Diagram (KLE650C Models other tha...
Page 513
Page 514 - Wiring Diagram (KLE650C Models US, CA an...
Page 515
Page 516 - Wiring Diagram (KLE650D Models)
Page 517
Page 518 - Precautions
Page 519 - Electrical Wiring
Page 520 - Battery
Page 521
Page 522 - Precautions
Page 523 - Interchange
Page 524 - Refreshing Charge
Page 525 - Charging System
Page 526 - Stator Coil Installation
Page 527 - Alternator Rotor Installation
Page 528 - Alternator Inspection
Page 529 - Regulator/Rectifier Inspection
Page 530
Page 531
Page 532 - Charging Voltage Inspection
Page 533
Page 534 - Starter Motor Clutch
Page 535 - Ignition System
Page 536 - Crankshaft Sensor Installation
Page 537 - Crankshaft Sensor Peak Voltage Inspectio...
Page 538 - Stick Coil Removal
Page 539 - Spark Plug Removal
Page 540 - Spark Plug Condition Inspection
Page 541 - IC Igniter Inspection
Page 542
Page 543
Page 544 - Starter Motor Removal
Page 545 - Starter Motor Disassembly
Page 546
Page 547 - Brush Inspection
Page 548 - Commutator Cleaning and Inspection
Page 549 - Right-hand End Cover Inspection
Page 550
Page 551 - Lighting System
Page 552 - City Light Bulb Replacement
Page 553 - Headlight Removal/Installation
Page 554 - License Plate Light Bulb Replacement
Page 555
Page 556 - Turn Signal Light Bulb Replacement
Page 557
Page 558
Page 559 - Air Switching Valve
Page 560 - Radiator Fan System
Page 561 - Meter, Gauge, Indicator Unit
Page 562 - Electronic Combination Meter Unit Inspec...
Page 563
Page 564
Page 565
Page 566
Page 567
Page 568
Page 569
Page 570
Page 571 - Switches and Sensors
Page 572 - Water Temperature Sensor Inspection
Page 573 - Speed Sensor Inspection
Page 574 - Oxygen Sensor Removal (Equipped Models)
Page 575 - Oxygen Sensor Installation (Equipped Mod...
Page 576 - Relay Box
Page 577 - Diode Circuit Inspection
Page 578
Page 579 - Fuse
Page 580 - ECU Fuse Removal
Page 581
Page 582
Page 583
Page 584
Page 585
Page 586
Page 587
Page 588
Page 589
Page 590
Page 591
Page 592
Page 593
Page 594
Page 595
Page 596
Page 597
Page 598
Page 599
Page 600
Page 601
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Page 603
Page 604
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Page 631
/
631
Contents
Table of contents
Troubleshooting
Bookmarks
Advertisement
Transmission
Transmission Assy Removal
•
Remove:
Shift Shaft Assembly (see External Shift Mechanism Re-
moval)
Neutral Switch Holder Screw [A]
Neutral Switch Holder [B] and Pin
Shift Drum Holder [C] and Pin
•
Remove the collar [A] and the O-ring [B] from the output
shaft [C].
•
Remove:
Clutch (see Clutch Removal in the Clutch chapter)
Transmission Case Bolts [A]
If the transmission assy is to be disassembled, remove
the following.
Shift Rod Plate Bolt and Plate [B]
Gear Positioning Lever [C] (see External Shift Mecha-
nism Removal)
•
Pull the transmission assy out of the crankcase.
Transmission Assy Installation
•
Be sure that the dowel pins [A] are in position.
•
Apply grease to the new O-ring [B] on the oil pipe [C].
•
Install the transmission assy on the crankcase.
•
Tighten:
Torque - Transmission Case Bolts: 20 N·m (2.0 kgf·m, 15
ft·lb)
CRANKSHAFT/TRANSMISSION 9-35
Table of
Contents
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Before Servicing
Unit Conversion Table
Hide
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Advertisement
Chapters
Table Of Contents
11
Periodic Maintenance
23
Fuel System (dfi)
83
Cooling System
193
Engine Top End
213
Clutch
259
Engine Lubrication System
273
7-16 Engine Lubrication System
289
Crankshaft/transmission
297
Wheels/tires
341
Final Drive
359
Brakes
377
Suspension
439
Steering
465
Frame
477
Electrical System
499
Table of Contents
Troubleshooting
Troubleshooting the DFI System
104
DFI System Troubleshooting Guide
110
ABS Troubleshooting Outline
411
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Kawasaki VERSYS Owner's Manual
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Kawasaki versys Owner's Manual
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KX450F Crankshaft/transmission
Kawasaki KX450F
Ninja ZX-10R2011 Transmission
Kawasaki Ninja ZX-10R2011
KDX200 Transmission Oil
Kawasaki KDX200
H1 Transmission
Kawasaki H1
Ninja H2 Transmission
Kawasaki Ninja H2
S75578KG3 Function Errors
AEG S75578KG3
Z250 1981 Transmission
Kawasaki Z250 1981
ninja zx-6rr Transmission
Kawasaki ninja zx-6rr
ninja zx-10r Transmission
Kawasaki ninja zx-10r
ninja zx-10r Transmission
Kawasaki ninja zx-10r
Z1000SX Transmission
Kawasaki Z1000SX
VN900 Custom Transmission
Kawasaki VN900 Custom
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Latest comments:
mo jin sa
Oct 28, 2016 08:32:
Very good manual!!! Very useful! Thank you very much!
mojinsa
Oct 28, 2016 08:07:
Very good manual!!! Very useful! Thank you very much!
mojinsa
Oct 28, 2016 08:20:
ok,很好
mojinsa
Oct 28, 2016 08:43:
ok,很好
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