Kawasaki WORKHORSE 250 (2003) [160/322] Shift fork ear thickness

9-20 CRANKSHAFT/TRANSMISSION

Transmission

Shift Drum Assembly

•

Tighten:

Torque - Shift Drum Pin Plate Bolt: 12 N·m (1.2 kgf·m, 104

in·lb)

Shift Fork Bending

•

Visually inspect the shift forks, and replace any fork that is

bent. A bent fork could cause difficulty in shifting, or allow

the transmission to jump out of gear when under power.

[A] 90°

Shift Fork Wear

•

Measure the thickness [A] of the shift fork ears, and di-

ameter [B] of the shift fork guide pin.

If the thickness and/or diameter of a shift fork is less than

the service limit, replace the shift fork.

Shift Fork Ear Thickness

Standard: 4.9 ∼ 5.0 mm (0.193 ∼ 0. 197 in.)

Service Limit: 4.8 mm (0.189 in. )

Shift Fork Guide Pin Diameter

Standard: 5.9 ∼ 6.0 mm (0.232 ∼ 0. 236 in.)

Service Limit: 5.8 mm (0.228 in. )

Shift Drum Inspection

•

Measure the shift drum grooves [A].

If any shift drum groove is worn over the service limit,

replace the drum.

Shift Drum Groove Width

Standard: 6.05 ∼ 6.20 mm (0.238 ∼ 0.244 in.)

Service Limit: 6.3 mm (0.248 in. )

Transmission Gear Inspection

•

Measure the shift drum grooves [A] in the transmission

gear.

If a shift fork groove in the gear is worn over the service

limit, replace the gear.

Gear Shift Fork Groove Width

Standard: 5.05 ∼ 5.15 mm (0.199 ∼ 0.203 in.)

Service Limit: 5.3 mm (0.209 in. )