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

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9-26 CRANKSHAFT/TRANSMISSION
Transmission
• Remove the ball bearing [A] from each shafts.
Special Tools - Bearing Puller: 57001–135 [B]
Bearing Puller Adapter: 57001–317 [C]
• Discard the bearing.
Transmission Shaft Assembly
• Apply engine oil to the sliding surfaces on the transmission
shafts, gears and bushings.
• 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
withasplinegroove[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 (see Transmission Assembly illustration).
○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 (see Transmission Assembly illustration).
○Install the 5th and 6th gears onto the output shaft with
their oil holes aligned.
○Install the 3rd/4th gear bushings onto the output shaft with
their oil holes aligned.