Kawasaki Z400 - Service manual > External Shift Mechanism

Shift Pedal Removal

• Remove the shift lever damp bolt [A], and disconnect the shift lever [B] from the shift shaft.
• Remove: Shift Pedal Bolt [C] Shift Pedal [D] Washer

Shift Pedal Installation

• Install: Washer [A] Shift Pedal [B]
• Apply a non-permanent locking agent to the shift pedal bolt [C].
• Apply grease to the sliding surface [D] of the shift pedal bolt.
• Tighten:

Toque -Shift Pedal Mounting Bolt: 25 N-m (2.5 kgf*m, 18 ft-lb)

• When installing the rubber damper [E], Face the chamfered side [F] inward.
• Align the line [A] on the shift shaft with the punch mark [B] on the shift lever.
• Tighten:

Toque - Shift Lever Clamp Bolt [C]: 12 N-m (1.2 kgf*m, 106 in-lb)

Adjust the tie-rod length [A] to 60.0 mm (2.36 in.).

Loosen the tie-rod locknuts [B] and turn the tie-rod.

The tie-rod locknut (front) has left-hand threads.

Tighten:

Torque -Tie-Rod Locknuts: 7.0 N-m (0.71 kgf-m, 62 in-lb)

External Shift Mechanism Removal

• Remove: Clutch (see Clutch Removal in the Clutch chapter)
• Remove the shift lever clamp bolt [A], and disconnect the shift lever [B] from the shift shaft.
• Remove: Circlip [C] Washer [D]

Special Tool - Outside Circlip Pliers: 57001-144

• Remove: Shift Shaft Assembly [A]

External Shift Mechanism installation

• Apply grease to the oil seal lips [A].

• Install: Shift Shaft Assembly [A] Fit the return spring pin [B] between the spring ends [C].

  Pull the shift mechanism arm [D], and hang it to the shift drum cam [E].

Install the washer [A].

Replace the circlip [B] with a new one, and install it.

Special Tool - Outside Circlip Pliers: 57 001-144

Fit the circlip into the groove of the shift shaft securely.

• Install the removed parts (see appropriate chapters).
• Check the shift shaft [A] for any damage.

*If the shaft is bent, straighten or replace it.

*If the serrations [B] are damaged, replace the shaft.

*If the springs [C] are damaged in any way, replace them.

*If the shift mechanism arm [Dl is damaged On any way, replace the shift shaft.

Check the shift shaft return spring pin [A] is not loose.

*If it is loose, unscrew it, apply a non-permanent locking agent to the threads, and tighten it.

Torque - Shift Shaft Return Spring Pin: 29 N*m (3.0 kgf*m, 21 ft-lb)

• Check the gear positioning lever [B] and b spring [C] for breaks or distortion.

*If the lever or spring is damaged in any way, replace it.

• Visually inspect the shift drum cam [D]

*If it is, badly worn or shows any damage, replace it

Ball Bearing, Needle Bearing, and Oil Seal

Ball and Needle Bearing Wear Inspection

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: