Kawasaki KX65 Motorcycle User Manual


 
ENGINE BOTTOM END/TRANSMISSION 7-13
Transmission
Shaft R emoval
Split the crankcase (see Crankcase Splitting).
Pull off the shift rods [A], and disengage the shift fork
guide pins from the shift drum grooves.
Remove the shift drum [B]
Remove the shift forks [C] from the transmission gears.
Take out the drive shaft [D] and output shaft [E] together,
with their gears meshed.
Shaft In s tallation
Hold the drive shaft [A] and output shaft [B] together, with
their gears meshed, and fit them into the right crankcase
half.
To install t he shift forks and shift drum, see the Shift Drum
and Fork Installation.
Shaft Disassembly
Remove the transmission shafts (see Shaft Removal).
Using circlip pliers to remove the circlips, disassemble the
transmission shaft.
Special Tool - Outside Circlip Pliers: 57001-144
Shaft Asse mbly
Apply transmission oil liberally to the transmission shaft,
gears and bearings.
Replace any circlips that were removed with new ones.
Always install circlips [A] so that the opening [B] is aligned
with a spline groove [C].
Special Tool - Outside Circlip Pliers: 57001-144
The drive s haft gears can be identified by size; the small-
est diameter gear is 1st gear, and the largest is 6th. Be
sure that all parts are put back in the correct sequence,
and facing the proper direction, and that all circlips and
the washers are properly in place.
[A] 1st Gear (13T; part of drive shaft)
[B] 6th Gear (24T; plain side faces right)
[C] 3rd/4th Gear (18T/21T; larger gear faces left)
[D] 5th Gear (23T; plain side faces l eft)
[E] 2nd Gear (16T; either side may face in)
[F] Circlip (1.2 × 15 × 19)