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. [. . . ] · The 5th gear [A]iton the output shaft has three steel balls assembled into for the positive neutral finder mechanism. To remove this gear from the shaft, quickly spin [B] the shaft in a vertical position while holding the 3rd gear [C], and pull off the 5th gear upwards. Special Tool - Outside Circlip Pliers: 57001-144 · The ball bearings and collar are press-fit on theatransmission shafts. To remove the bearings [A], use press or the bearing puller [B] and bearing puller adapter [C]. Special Tools - Bearing Puller: 57001-135 Bearing Puller Adapter: 57001-317 The output shaft ball bearing, O-ring and collar ought to No need for the bearing puller adapter at output shaft. be removed together. CRANKSHAFT/TRANSMISSION 8-23 Transmission Drive Shaft Assembly engine oil liberally to the drive shaft, gears, bear· Applyand bushing. ings · Install the drive shaft ball bearing using the bearing driver [A]. Special Tool - Bearing Driver, 32: 57001-382 any removed with new ones. · Replaceinstallcirclips that werethat the opening is aligned Always circlips [A] so with a spline groove [B], and install toothed washers [C] so that the teeth [D] are not aligned with the circlip opening [E]. To install a circlip without damage, fit the circlip onto the shaft expanding it just enough to install it, and use a suitable gear to push the circlip into place. assembling the shaft [A] · Whenthe shaft, align itsdrivehole [B]6th gear bushing the onto oil with the hole in shaft. drive shaft gears can be identified the small· Thediameter gear is 1st gear, and the by size: is 6th. Be est largest sure that all parts are put back in the correct sequence, facing the proper direction, and all circlips and washers are properly in place. Proper sequence starting with 1st gear (part of drive shaft) is: 1st gear, 5th gear (face the flat side of the gear to the right), washer, circlip, 3rd/4th gear (face 3rd gear side to the right), circlip, toothed washer, bushing (align the oil hole with the hole in the shaft), 6th gear (face the dogs to the right), toothed washer, circlip, 2nd gear, spacer, needle bearing, needle bearing outer race, and plug. The toothed washer before the bushing has slightly smaller teeth than the last one. · the onto the drive · Installside spacerball bearing. shaft, facing the chamfered to the that each gear · Checkwithout binding. spins or slides freely on the drive shaft 8-24 CRANKSHAFT/TRANSMISSION Transmission Output Shaft Assembly · Assembly is the reverse of disassembly. engine · Applybushing oil liberally to the output shaft, gears, bearings, and O-ring. shaft · Install the outputdriver. ball bearing, O-ring and collar using the bearing The ball bearing, O-ring and collar ought to be installed Special Tool - Bearing Driver, 32: 57001-382 · 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 assembling the · Whenthe shaft, align itsoutput shaft 3rd/4th gear bushing [A] to 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. effect of · Check thesteel ballsball-locking, after assembling the 5th gear and on the output shaft. Check that the 5th gear [A] does not come out of the output shaft when moving it up and down by hand. CRANKSHAFT/TRANSMISSION 8-25 Transmission gears size: · The output shaft gear iscan be identified bysmallestthe largest diameter 1st gear, and the is 6th. Be sure that all parts are put back in the correct sequence and facing the proper direction, and that all circlips and washers are properly in place. Proper sequence starting with 2nd gear is: 2nd gear (face the flat side of the gear to the left), toothed washer, circlip, 6th gear (face the fork groove side to the right), circlip, toothed washer, bushing (align the oil holes with the holes in the shaft), 4th gear (face the side with the dog recesses to the left), 3rd gear (face the side with the dog recesses to the right), toothed washer, circlip, 5th gear (face the fork groove side to the left) with steel balls (3), 1st gear (face the flat side of the gear to the right), spacer, needle bearing, and needle bearing outer race. Press the oil seal [A] onto the collar [B] so it is flush with the end of collar. [. . . ] Housing [A] Fuse Element [B] Terminals [C] Blown Element [D] CAUTION When replacing a fuse, be sure the new fuse matches the specified fuse rating for that circuit. Installation of a fuse with a higher rating may cause damage to wiring and components. APPENDIX 16-1 Appendix Table of Contents Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication (Periodic Maintenance) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [. . . ]