Service Manual (KLZ1000C) — page 305 of 762

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CRANKSHAFT/TRANSMISSION 9-41
Transmission
Shift Drum Assembly
• Install:
   Ball Bearing [A]
   Dowel Pin [B] and Shift Drum Cam [C]
○Align the pin with the groove in the shift drum cam.
• Apply  a non-permanent locking agent to the threads of
  the shift drum cam holder bolt [D] and tighten it.
  Torque - Shift Drum Cam Holder Bolt: 12 N·m (1.2 kgf·m,
              106 in·lb)

Shift Fork Bending Inspection
• 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.
   90° [A]

Shift Fork/Gear Groove Wear Inspection
• Measure  the thickness of the shift fork ears [A], and mea-
  sure the width of the gear grooves [B].
  If the thickness of a shift fork ear is less than the service
  limit, the shift fork must be replaced.
  Shift Fork Ear Thickness
    Standard:       5.9  6.0 mm (0.232  0.236 in.)
    Service Limit:    5.8 mm (0.228 in.)
  If the gear groove is worn over the service limit, the gear
  must be replaced.
  Gear Groove Width
    Standard:     6.05  6.15 mm (0.238  0.242 in.)
    Service Limit:    6.3 mm (0.25 in.)

Shift Fork Guide Pin/Drum Groove Wear
Inspection
• Measure the diameter of each shift fork guide pin [A], and
  measure the width of each shift drum groove [B].
  If the guide pin on any shift fork is less than the service
  limit, the fork must be replaced.
  Shift Fork Guide Pin Diameter
    Standard:       6.9  7.0 mm (0.272  0.276 in.)
    Service Limit:    6.8 mm (0.268 in.)
  If any shift drum groove is worn over the service limit, the
  drum must be replaced.
  Shift Drum Groove Width
    Standard:     7.05  7.20 mm (0.278  0.283 in.)
    Service Limit:    7.3 mm (0.29 in.)
  If the shift drum has been replaced, replace the gear po-
  sition sensor as a set.