Kawasaki Z1000SX - Service manual > Transmission Shaft Disassembly

Crankshaft/Transmission / Transmission / Transmission Shaft Disassembly

  • Remove the transmission shafts (see Transmission Shaft Removal).
  • Remove the circlips, and 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.

Transmission

  • Remove the ball bearing [A] from each shafts.

    Special Tools -
     Bearing Puller [C]: 57001-135
     Bearing Puller Adapter [D]: 57001-317

  • Discard the bearing.
    • For output shaft, remove the collar [B] together with the ball bearing.

Transmission

    See also:

     Kawasaki Z1000SX - Service manual > Transmission Shaft Removal

    Split the crankcase (see Crankcase Splitting). Remove the drive shaft [A] and output shaft [B].

     Kawasaki Z1000SX - Service manual > Transmission Shaft Assembly

    Install the new ball bearing [A] and collar [B] (output shaft) on the each shaft, using the bearing driver. Spacial Tool - Bearing Driver, 32: 57001-382 Apply engine oil to the bushings, ball bearings and shafts. Install the gear bushings [A] on the shaft with their holes [B] aligned. Replace any circlips removed with new ones. Install the circlips [A] so that the opening [B] is aligned with a spline groove [C]. 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 6th gear onto the output shaft with their oil holes aligned. Install the 3rd/4th gear bushings onto the output shaft with their oil holes aligned.

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