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.

NOTE

• When the toothed washers are assembled onto the output shaft, note the following.
• When the tangs [A] of the toothed washer shall be assembled, they should be installed into the notch [B] of the toothed washer.

• Fit the steel balls into the 5th gear holes in the output shaft, aligning the hole as shown in the figure.

  5th Gear [A]
  Output Shaft [B]
  Steel Balls [C]
  Hole [D]

NOTICE 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.

1. Output Shaft
2. Collar
3. Bearing
4. Bushing
5. 2nd Gear (39 T)
6. Washer ( 34 × 28.1)
7. Circlips ( 33 × 25.9)
8. Top Gear (25 T)
9. Toothed Washer ( 34)
10. 4th/3rd Gear (25 T/24 T)
11. Bushing
12. Toothed Washer ( 40.5)
13. Toothed Washer ( 37)
14. Steel Balls
15. 5th Gear (26 T)
16. Low Gear (39 T)
17. Washers ( 31 × 20.5)
18. Races
19. Needle Bearings
20. Circlips ( 22.2 × 18.7)
21. Needle Bearing
22. Low Gear (15 T) (Drive Shaft)
23. Bushing
24. 5th Gear (21 T)
25. Toothed Washer ( 31)
26. Circlip ( 29 × 22.6)
27. 3rd/4th Gear (15 T/18 T)
28. Bushing
29. Top Gear (22 T)
30. Toothed Washer ( 34.2)
31. Toothed Washer ( 32)
32. 2nd Gear (20 T)
33. Washer ( 30 × 20.5)

See also: