Shift Pedal Removal
Remove:
- Shift Lever Bolt [A]
- Shift Lever [B]
- Bolts [C]
- Left Front Footpeg Stay [D] with Shift Pedal [E]
![](https://motoinstruction.ru/img/kawasaki/23/128685.jpg)
Remove:
- Footpeg Holder Bolt [A]
- Footpeg [B]
- Shift Pedal [C]
![](https://motoinstruction.ru/img/kawasaki/23/128686.jpg)
Shift Pedal Installation
- When the new oil seals [A] are installed in the shift pedal housing [B], press and insert the oil seals in the shift pedal housing so that the oil seal surfaces are flush with the housing end [C] as shown.
![](https://motoinstruction.ru/img/kawasaki/23/128687.jpg)
Note: lnstall the oil seals so that the oil seal rip faces the shift pedal housing.
- Apply grease to the oil seal rip.
- Apply grease to the sliding surfaces [A] on the footpeg holder [B].
- Apply a non-permanent locking agent to the footpeg holder bolt [C].
Tighten:
Torque - Footpeg Holder Bolt: 34 Nm (3.5 kgf·m, 25 ft·lb)
Install:
- Left Front Footpeg Stay [D]
- Washer [E]
Tighten:
Torque - Front Footpeg Stay Bolts [F]: 25 Nm (2.5 kgf·m, 18 ft·lb)
![](https://motoinstruction.ru/img/kawasaki/23/128688.jpg)
- Align the mark [A] on the shift shaft with the mark [B] on the shift lever.
- Tighten the shift lever bolt [C] securely.
![](https://motoinstruction.ru/img/kawasaki/23/128689.jpg)
- Be sure the shift pedal [A] position is as shown.
- Shift Pedal Damper [B]
- About 136.1 mm (5.36 in.) [C]
Align the lower surface of the shift pedal to the upper surface of the shift pedal damper.
To adjust the pedal position, loosen the front locknut [D] (left-hand threads) and rear locknut [E] and then turn the tie-rod.
Tighten the tierod locknuts securely.
![](https://motoinstruction.ru/img/kawasaki/23/128690.jpg)
External Shift Mechanism Removal
- Drain the engine oil (See Engine Oil Change in the Periodic Maintenance chapter).
Remove:
- Engine Sprocket (See Engine Sprocket Removal in the Final Drive chapter)
- Neutral Switch Lead Connector [A]
- Shift Lever Bolt [B]
- Shift Lever [C]
- Shift Shaft Cover Bolts [D] and Clamp
- Shift Shaft Cover Screw [E]
- Shift Shaft Cover
![](https://motoinstruction.ru/img/kawasaki/23/128691.jpg)
- Remove the shift shaft assembly [A].
![](https://motoinstruction.ru/img/kawasaki/23/128692.jpg)
Remove:
- Clutch (See Clutch Removal in the Clutch chapter)
- Gear Positioning Lever Bolt [A]
- Spacer [B]
- Gear Positioning Lever [C]
Washer and Spring
![](https://motoinstruction.ru/img/kawasaki/23/128693.jpg)
External Shift Mechanism Installation
- Install the gear positioning lever [A] as shown.
- Spring [B]
- Washer [C]
- Spacer [D]
- Bolt [E]
Hook the spring at gear positioning lever, pushing up [F] the hook portion, as shown.
- Apply a non-permanent locking agent to the gear positioning lever bolt and tighten it.
Torque - Gear Positioning Lever Bolt: 12 N·m (1.2 kgf·m 106 in·lb)
![](https://motoinstruction.ru/img/kawasaki/23/128694.jpg)
- Apply [A] molybdenum disulfide oil solution to the rubbing surface between the lever [B] and pawl [C] and move them two or three times up and down to lubricate them.
- Be sure that the collar [D] is on the shaft.
- Be sure that the spring hook portions [E] are as shown.
![](https://motoinstruction.ru/img/kawasaki/23/128695.jpg)
- Install the shift shaft assembly [A].
- Be sure that the washer [B] is on the shaft.
- Be sure that the dowel pins [C] are in position.
![](https://motoinstruction.ru/img/kawasaki/23/128696.jpg)
- When the new needle bearing [A] is installed in the shift shaft cover [B], press and insert the new needle bearing until it is bottomed.
Special Tool - Bearing Driver Set: 57001-1129
- When the new oil seal [C] is installed in the shift cover, press and insert the new oil seal so that its surface is flush with the end of the hole.
Special Tool - Bearing Driver Set: 57001-1129
![](https://motoinstruction.ru/img/kawasaki/23/128697.jpg)
- Replace the shift shaft cover gasket with a new one.
- Install the shift shaft cover.
- Apply a non-permanent locking agent to the shift shaft cover screw [A] and bolts [B, C].
Do not apply a non-permanent locking agent to the shift shaft cover bolts [D, E].
- First tighten the cover bolts, then tighten the cover screw.
Torque - Shift Shaft Cover Bolts: 9.8 Nm (1.0 kgf·m, 87 in·lb)
Shift Shaft Cover Screw: 4.9 Nm (0.50 kgf·m, 43 in·lb)
![](https://motoinstruction.ru/img/kawasaki/23/128698.jpg)
External Shift Mechanism Inspection
- Examine the shift shaft [A] for any damage.
If the shaft is bent, straighten or replace it.
If the serration [B] are damaged, replace the shaft.
If the springs [C] are damaged in any way, replace them.
If the shift mechanism arm [D] is damaged in any way, replace the shaft.
![](https://motoinstruction.ru/img/kawasaki/23/128699.jpg)
- Check the return spring pin [A] is not loose.
If it is loose, unscrew it, apply a non-permanent locking agent to the threads, and tighten it.
Torque - Shift Shaft Return Spring Pin: 29 Nm (3.0 kgf·m, 21 ft·lb)
![](https://motoinstruction.ru/img/kawasaki/23/128700.jpg)
- Check the gear positioning lever [A] and its spring for breaks or distortion.
If the lever or spring are damaged in any way, replace them.
- Visually inspect the shift drum cam [B].
If they are badly worn or if they show any damage, replace it.
![](https://motoinstruction.ru/img/kawasaki/23/128701.jpg)
Transmission Assy Removal
Remove:
- Shift Shaft Assembly (See External Shift Mechanism Removal)
- Neutral Switch Holder Screw [A]
- Neutral Switch Holder [B] and Pin
- Shift Drum Holder [C] and Pin
![](https://motoinstruction.ru/img/kawasaki/23/128702.jpg)
Remove:
- Collar [A]
- O-ring [B]
![](https://motoinstruction.ru/img/kawasaki/23/128703.jpg)
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 [B]
- Shift Rod Plate [C]
- Gear Positioning Lever [D] (See External Shift Mechanism Removal)
![](https://motoinstruction.ru/img/kawasaki/23/128704.jpg)
- Pull the transmission assy [A] out of the crankcase.
![](https://motoinstruction.ru/img/kawasaki/23/128705.jpg)
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 Nm (2.0 kgf·m, 15 ft·lb)
![](https://motoinstruction.ru/img/kawasaki/23/128706.jpg)
If the gear positioning lever [A] was removed, install it (See External Shift Mechanism Installation).
If the shift rod plate [B] was removed, install it.
Engage the shift rod plate to the groove of the shift rod [C], and apply a non-permanent locking agent to the shift rod plate bolt and tighten it.
Torque - Shift Rod Plate Bolt: 9.8 Nm (1.0 kgf·m, 87 in·lb)
- Set the gear positioning lever to the neutral position [D].
- Check that the drive and output shaft turn freely.
![](https://motoinstruction.ru/img/kawasaki/23/128707.jpg)
Install:
- Pin [A]
- Shift Drum Holder [B]
- Pin [C]
- Neutral Switch Holder [D]
- Apply a non-permanent locking agent to the neutral switch holder screw [E] and tighten it.
Torque - Neutral Switch Holder Screw: 4.9 Nm (0.50 kgf·m, 43 in·lb)
![](https://motoinstruction.ru/img/kawasaki/23/128708.jpg)
- Apply grease to the new O-ring [A] and install its position on the output shaft.
- Apply grease to the oil seal rip.
- Install the collar [B].
- When the new oil seal [C] is installed in the crankcase, press in the oil seal onto the collar so that the surface of the oil seal is flush with the surface [D] of the crankcase.
Apply a soap and water solution or rubber lubricant to the outer circumference [E] of the oil seal so that it will go into place smoothly.
![](https://motoinstruction.ru/img/kawasaki/23/128709.jpg)
Transmission Assy Disassembly
- Remove the transmission assy (See Transmission Assy Removal).
- Remove the following from the transmission case [A].
- Shift Rods [B]
- Shift Forks [C]
- Drive Shaft [D]
- Output Shaft [E]
![](https://motoinstruction.ru/img/kawasaki/23/128710.jpg)
Remove:
- Shift Drum Cam Bolt [A]
- Shift Drum [B] and Pin
- Shift Drum [C]
![](https://motoinstruction.ru/img/kawasaki/23/128711.jpg)
Transmission Assy Assembly
- When the new ball bearing [A] and new race [B] are installed in the transmission case [C], press and insert them until they are bottomed.
Special Tool - Bearing Driver Set: 57001-1129
Note: lnstall the new ball bearing and new race so that the stepped side [D] faces inside of the transmission case.
- When the ball bearing [E] for shift drum is installed in the transmission case, insert the ball bearing until it is bottomed.
![](https://motoinstruction.ru/img/kawasaki/23/128712.jpg)
- Install the shift drum bearing holder [A].
- Apply a non-permanent locking agent to the threads of the shift drum bearing holder screws [B] and tighten them.
Torque - Shift Drum Bearing Holder Screws: 4.9 Nm (0.50 kgf·m 43 in·lb)
![](https://motoinstruction.ru/img/kawasaki/23/128713.jpg)
- Install the drive shaft bearing holder [A].
- Apply a non-permanent locking agent to the threads of the drive shaft bearing holder screw [B] and tighten it.
Torque - Drive Shaft Bearing Holder Screw: 4.9 Nm (0.50 kgf·m 43 in4b)
![](https://motoinstruction.ru/img/kawasaki/23/128714.jpg)
- Install the following on the transmission case [A].
- Shift Drum [B]
- Pin [C]
- Shift Drum Cam [D]
Align the pin with the hole on the shift drum cam.
- Apply a non-permanent locking agent to the shift drum cam bolt [E] and tighten it.
Torque - Shift Drum Cam Bolt: 12 Nm (1.2 kgf·m, 106 in·lb)
- Install the following as a set.
- Drive Shaft [F]
- Output Shaft [G]
- Install the forks as shown.
Position the one [H] with shortest ears on the drive shaft and place the pin in the center groove in the shift drum.
The two forks [J] on the output shaft are identical.
- Install the shift rods, noting the groove position.
The rod [K] length of the output shaft side is shorter than the rod [L] length of the drive shaft side.
- Apply molybdenum disulfide oil solution to the transmission gears shown with X marks [M].
- Be sure that the spacer [N] is on the output shaft.
- Install the transmission assy (See Transmission Assy Installation).
![](https://motoinstruction.ru/img/kawasaki/23/128715.jpg)
Transmission Shaft Removal
- Refer to the Transmission Assy Disassembly.
Transmission Shaft Installation
- Refer to the Transmission Assy Assembly.
Transmission Shaft Disassembly
- Remove the transmission shafts (See Transmission Assy Disassembly).
- Remove the circlips, disassemble the transmission shafts.
Special Tool - Outside Circlip Pliers: 57001-144
- The 5th gear [A] on the output shaft has three steel balls assembled into it for the positive neutral finder mechanism. Remove the 5th gear.
Set the output shaft in a vertical position holding the 3rd gear [B].
Spin the 5th gear quickly [C] and pull it off upward.
![](https://motoinstruction.ru/img/kawasaki/23/128716.jpg)
Transmission Shaft Assembly
- Apply engine oil to the bushings, needle bearings and shafts.
- Install the gear bushings [A] on the shaft with their holes [B] aligned.
![](https://motoinstruction.ru/img/kawasaki/23/128717.jpg)
- Replace any circlips removed with new ones.
- Install the circlips [A] so that the opening [B] is aligned with a spline groove [C].
![](https://motoinstruction.ru/img/kawasaki/23/128718.jpg)
- The drive shaft gears can be recognized by size: the gear with the smallest diameter is 1st gear, and the largest one is 6th gear. Be sure that all parts are put back in the correct sequence and all circlips and washers are properly in place.
- Install the 3rd/4th gear onto the drive shaft with their oil holes aligned.
- Install the 6th gear bushing onto the drive shaft with their oil holes aligned.
- The output shaft gears can be recognized by size: the gear with the largest diameter is 1st gear, and the smallest one is 6th gear. Be sure that all parts are put back in the correct sequence and all circlips and washers are properly in place.
- Install the 5th and 6th gears onto the output shaft with their oil holes aligned.
- Install the 3rd/4th gear bushings onto the output shaft with their oil holes aligned.
- Fit the steel balls into the 5th gear holes in the output shaft, aligning three oil holes.
- 5th Gear [A]
- Output Shaft [B]
- Steel Balls [C]
- Oil Holes [D]
![](https://motoinstruction.ru/img/kawasaki/23/128719.jpg)
Caution: Do not apply grease to the balls to hold them in place. This will cause the positive neutral finder mechanism to malfunction.
After assembling the 5th gear with steel balls in place on the output shaft, check the ball-locking effect that the 5th gear doesn't come out of the output shaft when moving it up and down by hand.
- Check that each gear spins or slides freely on the transmission shafts without binding after assembly.
![](https://motoinstruction.ru/img/kawasaki/23/128720.jpg)
1. Drive Shaft; 2. 1st Gear; 3. 2nd Gear; 4. 3rd Gear; 5. 4th Gear; 6. 5th Gear; 7. 6th (Top) Gear; 8. Bushing; 9. Toothed Washer, ∅34 mm (1.34 in.); 10. Circlip; 11. Bushing; 12. Thrust Washer, ∅30 mm (1.18 in.); 13. Needle Bearing; 14. Circlip; 15. Output Shaft; 16. Spacer, ∅39 mm (1.54 in.); 17. Washer, ∅40 mm (1.57 in.); 18. Bushing; 19. Toothed Washer, ∅38 mm (1.50 in.); 20. Shim, ∅28 mm (1.10 in.); 21. Steel Ball; 22. Circlip, ∅32.2 mm (1.268 in.); 23. Thrust Washer, ∅25 mm (0.98 in.)
Shift Drum and Fork Removal
- Refer to the Transmission Assy Disassembly.
Shift Drum and Fork Installation
- Refer to the Transmission Assy Assembly.
Shift Drum Disassembly
- Refer to the Transmission Assy Disassembly.
Shift Drum Assembly
- Refer to the Transmission Assy Assembly.
Shift Fork Bending
- Visually inspect the shift forks, and replace any fork that is bent. A bent fork could cause difficulty in shifting, or allow the transmission to jump out of gear when under power.
- 90° [A]
![](https://motoinstruction.ru/img/kawasaki/23/128721.jpg)
Shift Fork/Gear Groove Wear
- Measure the thickness of the shift fork ears [A], and measure the width [B] of the gear grooves.
If the thickness of a shift fork ear is less than the service limit, the shift fork must be replaced.
Shift Fork Ear Thickness
Standard: 5.9-6.0 mm (0.232-0.236 in.)
Service Limit: 5.8 mm (0.228 in.)
If the gear groove is worn over the service limit, the gear must be replaced.
Gear Groove Width
Standard: 6.05-6.15 mm (0.238-0.242 in.)
Service Limit: 6.25 mm (0.246 in.)
![](https://motoinstruction.ru/img/kawasaki/23/128722.jpg)
Shift Fork Guide Pin/Drum Groove Wear
- Measure the diameter of each shift fork guide pin [A], and measure the width [B] of each shift drum groove.
If the guide pin on any shift fork is less than the service limit, the fork must be replaced.
Shift Fork Guide Pin Diameter
Standard: 6.9-7.0 mm (0.272-0.276 in.)
Service Limit: 6.8 mm (0.268 in.)
If any shift drum groove is worn over the service limit, the drum must be replaced.
Shift Drum Groove Width
Standard: 7.05-7.20 mm (0.278-0.283 in.)
Service Limit: 7.3 mm (0.287 in.)
![](https://motoinstruction.ru/img/kawasaki/23/128723.jpg)
Gear Dog and Gear Dog Hole Damage
- Visually inspect the gear dogs [A] and gear dog holes [B].
Replace any damaged gears or gears with excessively worn dogs or dog holes.
![](https://motoinstruction.ru/img/kawasaki/23/128724.jpg)