Kawasaki KLE500 (2004) [215/401] Crankshaft transmission 9 29

CRANKSHAFT/TRANSMISSION 9-29

Transmission

•

Install the spacer onto the drive shaft, facing the cham-

fered side to the ball bearing.

•

Check that each gear spins or slides freely on the drive

shaft without binding.

Output Shaft Assembly

•

Assembly is the reverse of disassembly. Note the follow-

ing.

•

Apply engine oil liberally to the output shaft, gears, bear-

ings, bushing and O-ring.

•

Install the output shaft ball bearing, O-ring and collar us-

ing the bearing driver.

Special Tool - Bearing Driver, 32: 57001-382

○

The ball bearing, O-ring and collar ought to be installed

individually.

•

Replace any circlips that were removed with new ones.

○

Always install circlips so that the opening is aligned with

a spline groove. To install a circlip without damage, fit the

circlip onto the shaft expanding it only enough to install it,

and use a suitable gear to push the circlip into place.

[A] Circlip

[B] Toothed Washer

•

When assembling the output shaft 3rd/4th gear bushing

[A] to the shaft, align its oil holes [B] with the holes in the

shaft.

CAUTION

When installing the 5th gear and steel balls on the

output shaft, do not apply grease to the balls to hold

them in place. This will cause the positive neutral

finder mechanism to malfunction.