Kawasaki Z1000 - ZR1000 2003-04 Service Manual - Small Engine ...

Transmission
CRANKSHAFT/TRANSMISSION 9-25
Transmission Shaft Removal
Split the crankcase (see Crankcase Splitting).
• Remove the drive shaft [A] and output shaft [B].
Transmission Shaft Installation
• Check to see that the set pins [A] and set rings [B] are in
place.
• Install the drive shaft and output shaft into the upper
crankcase half.
• Apply engine oil to the sliding surfaces of the gears and
bearings.
○The bearing set pins and rings must match properly with
the holes or grooves in the bearing outer races. When
they are properly matched, there is no clearance [A] between
the crankcase and the bearing outer races.
Assemble the crankcase.
•
Press in the oil seal [A] onto collar [B] so that the surface
of the oil seal is flush with the counterbore bottom surface
[C] of the crankcase.
Transmission Shaft Disassembly
• Remove the transmission shafts (see Transmission Shaft
Removal).
• Remove the circlips, disassemble the transmission
shafts.
• 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 as follows.
○Set the output shaft in a vertical position holding the 3rd
gear [B].
○Spin the 5th gear quickly [C] and pull it off upward.
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