External shift mechanism removal
Remove:
- Shift Pedal (see Shift pedal removal)
- Alternator Outer Cover (see Alternator outer cover removal in the Electrical System chapter)
- Engine Pulley (see Engine pulley removal in the Final Drive chapter)
- Pry Open the clamp [A]
- Bolts [B]
- Engine Pulley Plate [C]
![](https://motoinstruction.ru/img/kawasaki/13/119145.jpg)
Remove:
- Front and Rear Shift Levers [A]
![](https://motoinstruction.ru/img/kawasaki/13/119146.jpg)
Remove:
- Bolts [A]
- External Shift Mechanism Cover [B] together with the Shift Shaft [C]
Remove the these bolts [D] with the cover.
![](https://motoinstruction.ru/img/kawasaki/13/119147.jpg)
Remove:
- Bolt [A]
- Spring [B]
- Gear Set Lever [C]
![](https://motoinstruction.ru/img/kawasaki/13/119148.jpg)
External shift mechanism installation
Install the gear set lever [A] and spring [B], and tighten the bolt [C].
- Torque - Gear Set Lever Bolt: 9.8 N·m (1.0 kgf·m, 87 in·lb)
Install the dowel pins [D] and new cover gasket.
Apply grease to the oil seal lip.
Install the washer to the shift shaft, then insert the shaft into the cover.
![](https://motoinstruction.ru/img/kawasaki/13/119149.jpg)
Set the these cover bolts [A] to the cover before cover installed.
Install the cover with the shaft to the crankcase.
Tighten:
- External Shift Mechanism Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
![](https://motoinstruction.ru/img/kawasaki/13/119150.jpg)
Install the front shift lever [A] to the shift pedal shaft so that the punched mark [B] on the shaft is aligned with the punched marked [C] on the front shift lever.
![](https://motoinstruction.ru/img/kawasaki/13/119151.jpg)
Install the rear shift lever [A] on the shift shaft so that the punched mark [B] on the shaft is aligned with the punched mark [C] on the rear shift lever.
Install the left footboard (see Footboard removal/installation in the Frame chapter).
![](https://motoinstruction.ru/img/kawasaki/13/119152.jpg)
Loosen the locknuts [A] and turn the shift rod [B] so that the outside length [C] of the locknuts is 149±1 mm (5.87±0.04 in.).
![](https://motoinstruction.ru/img/kawasaki/13/119153.jpg)
The rear locknut has left-hand threads.
Torque:
- Shift Rod Locknut (Front): 9.8 N·m (1.0 kgf·m, 87 in·lb)
- Shift Rod Locknut (Rear): 9.8 N·m (1.0 kgf·m, 87 in·lb)
- Rear Shift Lever Clamp Bolt: 12 N·m (1.2 kgf·m, 106 in·lb)
Check that the rear shift pedal is 30 mm (1.2 in.) [A] above top of the footboard.
![](https://motoinstruction.ru/img/kawasaki/13/119154.jpg)
External shift mechanism inspection
Examine the shift shaft [A] for any damage.
★ If the shaft is bent, straighten or replace it.
★ If the splines [B] are damaged, replace the shaft.
★ If the springs [C] are damaged in anyway, replace them.
★ If the shift mechanism arm [D] is damaged in any way, replace it.
![](https://motoinstruction.ru/img/kawasaki/13/119155.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 N·m (3.0 kgf·m, 21 ft·lb)
Check the shift drum position lever [B] and spring [C] for breaks or distortion.
★ If the lever or spring is damaged in any way, replace it.
Visually inspect the shift drum cam [D].
![](https://motoinstruction.ru/img/kawasaki/13/119156.jpg)
★ If it is badly worn or shows any damage, replace it.