Kawasaki KX250F (2004) [221/357] Http manuals magnamaniac com
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Kawasaki KX250F (2004) [221/357] Http manuals magnamaniac com

Kawasaki KX250F (2004) [221/357] Http manuals magnamaniac com
9-16 CRANKSHAFT/TRANSMISSION
Transmission
•
Apply a small amount of engine oil to the shift fork fingers
and fit each shift fork into the groove of the proper gear.
•
The shift forks can be identified by their shape or mark.
Install them noting the direction shown.
○
The drive shaft fork [A] is the shortest, and install it with
its mark “IN” [B] facing the engine left side.
○
Install the right output shaft fork [A] with its mark “R” [B]
facing the engine right side.
○
Install the left output shaft fork [C] with its mark “L” [D]
facing the engine left side.
•
Fit each shift fork guide pin into the corresponding groove
in the shift drum.
•
Apply a small amount of engine oil to the shift rods and
slide them into the shift forks.
•
Install the oil screens [A] as shown.
Longer O utcrop [B]
Right Crankcase [C]
•
Assembly the crankcase (see this chapter).
Transmission Shaft Dis assembly
•
Remove the transmission shafts.
•
Remove the circlips, washers, then gears.
Special Tool - Outside Circlip Pliers: 57001–144
•
Do not reuse the removed circlips.
Transmission Shaft Assembly
•
Apply engine oil liberally to the transmission shaft, gears
and bearings.
•
Replace any circlips that w ere removed with new ones.
○
Always install the circlips [A] so that the opening [B] is
aligned with a spline groove [C], and install toothed wash-
ers. To install a circlip without damage, first f it the circlip
onto the shaft expanding it just enough to install it, and
then use a suitable gear to push the circlip into place.
Special Tool - Outside Circlip Pliers: 57001–144
•
The drive shaft gears can be identified by size; the small-
est diameter gear is 1st gear, and the largest is 5th. Be
sure that all parts are put back in the correct sequence,
facing the proper direction, and that all circlips and the
washers are properly in place.

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