Kawasaki Z1000SX - Service manual > External Shift Mechanism Installation

• Be sure to install the dowel pin [A].
• Align the dowel pin with the hollow [B] of the shift drum cam.
• Apply a non-permanent locking agent to the threads of the shift drum cam bolt, and tighten it.

  Torque - Shift Drum Cam Bolt: 12 N*m (1.2 kgf*m, 106 in*lb)

• Assemble the following parts as shown.
  [A] Gear Positioning Lever
  [B] Spring
  [C] Collar
  [D] Gear Positioning Lever Bolt
  • Hang the spring end [E] to the gear positioning lever.

• While prying the gear positioning lever [A], tighten the gear positioning lever bolt [B].

  Torque - Gear Positioning Lever Bolt: 12 N*m (1.2 kgf*m, 106 in*lb)

• Install the shift shaft [A] so that the return spring pin [B] fits between the spring [C].

• Install the washer [A].
• Replace the circlip [B] with a new one, and install it.

  Special Tool - Out side Circlip Pliers: 57001-144

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 shift shaft.

• 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: 39 N*m (4.0 kgf*m, 29 ft*lb)

• 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 it is badly worn or shows any damage, replace it.

See also: