Transmission. External Shift Mechanism Removal • Remove:

External Shift Mechanism Removal • Remove:

Left Front Footpeg

Shift Pedal Link Lever

Engine Sprocket (see Engine Sprocket Removal in the

Final Drive chapter)

Chain Guard [A]

Neutral Switch Lead Connector [B]

• Place an oil pan beneath the external shift mechanism cover [A]. Remove the external shift mechanism cover bolts [B].

• Pull the cover.

• Remove the cover with the shift shaft assembly while pushing the shift mechanism arm [A] down..

• Remove the nut [A] and take off the gear positioning lever [B] The lever has a collar [C], spring [D], and washer.

External Shift Mechanism Installation OThe small diameter side of the collar in the gear position­ing lever must face toward the crankcase.

• Tighten the positioning lever nut [A].

Torque - Gear Positioning Lever Nut: 11 N-m (1.1 kgf-m, 95 in-lb)

• Check that the return spring pin [B] is not loose.

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

Torque - Return Spring Pin: 20 N-m (2.0 kgf-m, 14.5 ft-lb)

• Apply silicone sealant to the area [C].

Sealant - Kawasaki Bond (Silicone Sealant): 56129-120

Replace the cover gasket with a new one.

9-26 CRANKSHAFT/TRANSMISSION