Kawasaki KX250F (2004) [179/357] Http manuals magnamaniac com
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Kawasaki KX250F (2004) [179/357] Http manuals magnamaniac com

Kawasaki KX250F (2004) [179/357] Http manuals magnamaniac com
6-18 ENGINE RIGHT SIDE
External Shift Mechanism
•
Set up the shift ratchet assembly as shown in the figure.
Ratchet [A]
Pawls [B]
Pins [C]
Springs [D]
Crankcase Side [E]
•
Then install the ratchet assembly [A] to the ratchet plate
[B] as shown i n the figure.
Crankcase Side [C]
•
Install the ratchet assembly to the shift drum cam.
•
Apply a non-permanent locking agent to the screw.
•
Tighten:
Torque - Ratchet Pla te M ounting Bolt: 9.8 N·m (1.0 kgf·m,
87 in·lb)
Ratchet Plate Mounting Screw: 6.4 N·m ( 0.6 kgf·m,
87 in·lb)
•
Align the middle tooth [A] of the ratchet gear with the pin
[B].
•
Before installing the shift shaft, apply high temperature
grease to the oil seal lips and shift shaft splines.
•
Insert the shift shaft [C].
○
Be sure to install the washer [D].
•
Install:
Clutch (see this chapter)
Right Engine Cover (see this chapter)
•
Install the shift pedal [A] as shown.
50.5 mm (1.988 in.) [B]
•
Tighten:
Torque - Shift Pedal Bolt: 9.8 N·m (1.0 kgf·m, 87 in·lb)
External Shift Mechanism Inspection
•
Check the shift s haft [A] for bending or damage to the
splines.
If the shaft is bent, straighten or replace it. If the splines
are damaged, replace the shift mechanism.
•
Check the return spring [B] for cracks or distortion.
If the spring is dam aged in any way, replace it.
•
Check the shift lever [C] for distortion.
If the shift lever is damaged in any way, replace the shift
shaft.

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