User manual KAWASAKI ER-5 SERVICE MANUAL

[. . . ] Quick Reference Guide General Information Fuel System Cooling System Engine Top End Clutch Engine Lubrication System Engine Removal/Installation Crankshaft/Transmission Wheels/Tires Final Drive Brakes Suspension Steering Frame Electrical System Appendix This quick reference guide will assist you in locating a desired topic or procedure. ·Bend the pages back to match the black tab of the desired chapter number with the black tab on the edge at each table of contents page. ·Refer to the sectional table of contents for the exact pages to locate the specific topic required. 1j 2j 3j 4j 5j 6j 7j 8j 9j 10 j 11 j 12 j 13 j 14 j 15 j 16 j ER-5 Motorcycle Service Manual All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Department/Consumer Products & Machinery Company/Kawasaki Heavy Industries, Ltd. , Japan. [. . . ] 92028-1497 92028-1495 92028-1496 92028-1692 92028-1690 92028-1691 None None None None 8-20 CRANKSHAFT/TRANSMISSION Transmission External Shift Mechanism Removal Chain Guard [A] Neutral Switch Lead Connector [B] · Remove:Sprocket (see Final Drive chapter) Engine an · Place [A]. oil pan beneath the external shift mechanism cover · Remove the external shift mechanism cover bolts [B]. · Pull the cover. cover with the shift shaft assembly while the · Remove the shift mechanism arm [A]. pushing the · Removelevernut [A] and take off the gear positioning lever [B] The has a collar [C], spring [D], and washer. External Shift Mechanism Installation The small diameter side of the collar in the gear position- · ing lever must face toward the crankcase. Tighten the positioning lever nut [A]. that the return · Check loose, remove spring pina[B] is not loose. locking If it is it, apply non-permanent agent to the threads, and tighten it. Replace the cover gasket with a · Torque - Return Spring Pin: 20 N·m (2. 0 kgf·m, 14. 5 ft·lb) Torque - Gear Positioning Lever Nut: 11 N·m (1. 1 kgf·m, 95 in·lb) CRANKSHAFT/TRANSMISSION 8-21 Transmission high temperature grease to the seal lips. · Apply the shift shaft into the cover [A], and then fit the shift · Insert mechanism arm [B] to the shift drum [C]. · Tighten the cover bolts. · Check: Oil Level (see Engine Lubrication System chapEngine ter) Drive Chain Slack (see Final Drive chapter) Torque - External Shift Mechanism Cover Bolts: 11 N·m (1. 1 kgf·m. 95 in·lb) External Shift Mechanism Inspection · Examine the shift shaft for any damage. Check the return spring [B] and arm spring [C] for breaks or distortion. that the return · Checkloose, unscrew spring pina[A] is not loose. locking If it is it, apply non-permanent agent to the threads, and tighten it. levers [B], and their springs [C] for Torque - Return Spring Pin: 20 N·m (2. 0 kgf·m, 14. 5 ft·lb) · If the levers or springs are damaged in any way, replace them. If they are badly worn or if they show any damage, replace them. Transmission Shaft Removal · Remove the engine (see Engine Removal/Installation chapter). pull the shaft assemshaft assembly, and · Lift up the driveclutch housing. Leave the clutch housing bly out of the and primary chain in place. 8-22 CRANKSHAFT/TRANSMISSION Transmission Transmission Shaft Installation clean off the outer cir· With a high flash-point solvent, ball bearings and needle cumferences of the transmission · bearings, and their bearing housings, and wipe dry. Check to see that the set rings [A] and set pins [B] are in place in the transmission bearing housings. the and primary chain, insert the · Lift upshaft clutch housing the clutch housing, and install drive assembly into the drive shaft assembly in the upper crankcase half. The bearing set pins and rings must match properly with the holes or grooves in the bearing outer races. When they match properly, there is no clearance [A] between the crankcase and the bearing outer races. · the crankcase. · Install the Transmission Shaft Disassembly · Remove the transmission shaft. remove the circlips, dis· Using the outside circlip pliers to assemble the transmission shafts. · The 5th gear [A]iton the output shaft has three steel balls assembled into for the positive neutral finder mechanism. [. . . ] lift up · Unlock · Pull the fuse [C] straight out of the fuse box with needle nose pliers. Fuse Installation fails during operation, inspect · If a fusedetermine the cause, and thenthe electrical system to replace it with a · new fuse of proper amperage. Install the fuse box fuses on the original position as specified on the lid. Fuse Inspection the fuse. Before replacing a · If it is fuse, always check the amperage in the affected blown circuit. If the amperage is equal to or greater than the fuse rating, check the wiring and related components for a short circuit. [. . . ]