Kawasaki Z1000SX - Service manual > Shift Drum and Fork Removal

• Remove:
  Lower Crankcase Half (see Crankcase Splitting)
  Transmission Shafts (see Transmission Shaft Removal)
  Gear Positioning Lever (see External Shift Mechanism Removal)
  Bolts [A]
  Shift Drum Bearing Holder [B]
• Pull out the shift rods [C], and take off the shift forks.
• Pull out the shift drum [D].

Shift Drum and Fork Installation

• Apply engine oil to the shift drum, forks and rods.
• Install the shift rods [A], noting the groove position.
  • The rods are identical.
  • Position the one with shortest ears [B] on the drive shaft and place the pin in the center groove in the shift drum [C].
• The two forks [D] on the output shaft are identical. -Install the forks so that its "0061" and "0062" side faces engine left side.
• Apply a non-permanent locking agent to the threads of the shift drum bearing holder bolts, and tighten them.

  Torque - Shift Drum Bearing Holder Bolts: 12 N*m (1.2 kgf*m, 106 in*lb)

Shift Drum Disassembly

• Remove the shift drum (see Shift Drum and Fork Removal).
• While holding the shift drum with a vise, remove the shift drum cam bolt [A].
• Remove:
  Shift Drum Cam [B]
  Dowel Pin [C]
  Bearing [D]

Shift Drum Assembly

• Be sure to install the dowel pin.
• Apply a non-permanent locking agent to the threads of the shift drum bearing holder bolt, and tighten it.

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

Shift Fork Bending Inspection

• 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.

  90º [A]

Shift Fork/Gear Groove Wear Inspection

• Measure the thickness of the shift fork ears [A], and measure the width of the gear grooves [B].

  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.)

Shift Fork Guide Pin/Drum Groove Wear Inspection

• Measure the diameter of each shift fork guide pin [A], and measure the width of each shift drum groove [B].

  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.)

Gear Dog and Gear Dog Hole Damage Inspection

• Visually inspect the gear dogs [A] and gear dog holes [B].

  Replace any damaged gears or gears with excessively worn dogs or dog holes.

Ball Bearing, Needle Bearing, and Oil Seal

Ball and Needle Bearing Replacement

NOTICE Do not remove the ball or needle bearings unless it is necessary. Removal may damage them.

• Using a press or puller, remove the ball bearing and/or needle bearings.

NOTE

• In the absence of the above mentioned tools, satisfactory results may be obtained by heating the case to approximately 93ºC (200ºF) max., and tapping the bearing in or out.

NOTICE Do not heat the case with a torch. This will warp the case. Soak the case in oil and heat the oil.

• Using a press and the bearing driver set [A], install the new ball bearing until it stops at the bottom of its housing.
  • The new needle bearings must be pressed into the crankcase so that the end is flush with the end of the hole.

Special Tool - Bearing Driver Set: 57001-1129

Ball and Needle Bearing Wear

NOTICE Do not remove the bearings for inspection. Removal may damage them.

• Check the ball bearings.
  • Since the ball bearings are made to extremely close tolerances, the wear must be judged by feel rather than measurement.

    Clean each bearing in a high-flash point solvent, dry it (do not spin the bearing while it is dry), and oil it with engine oil.

  • Spin [A] the bearing by hand to check its condition.

    If the bearing is noisy, does not spin smoothly, or has any rough spots, replace it.

• Check the needle bearings.
  • The rollers in a needle bearing normally wear very little, and wear is difficult to measure. Instead of measuring, inspect the bearing for abrasion, color change, or other damage.

If there is any doubt as to the condition of a needle bearing, replace it.

Oil Seal Inspection

• Inspect the oil seals.

  Replace it if the lips are misshapen, discolored (indicating that the rubber has deteriorated), hardened or otherwise damaged.

See also: