•

Torque - Shift Drum Cam Holder Bolt: 24 N·m (2.4 kgf·m, 18
ft·lb)

9-42 CRANKSHAFT/TRANSMISSION
Transmission
the drive shaft [A] and output shaft [B] as a set in
• Install
the transmission case [C].
the shift forks as shown.
•○Install
The shift fork [D] for drive shaft has “A2” mark. Face the
mark to the upside.
○The shift forks [E] for output shaft have “A1” mark. Face
the mark to the bottom.
○The shift forks [F] for output shaft have “A3” mark. Face
the mark to the bottom.
Install the shift rod [G].
Apply molybdenum disulfide oil solution to the transmission gears (x marks) [H].
Install the washer [I] on the output shaft.

•
•
•

Transmission Shaft Removal

• Refer to the Transmission Assy Disassembly.
Transmission Shaft Installation

• Refer to the Transmission Assy Assembly.
Transmission Shaft Disassembly

the transmission shafts (see Transmission Shaft
• Remove
Removal).
the circlips, and then disassemble the transmis• Remove
sion shafts.
Special Tool - Outside Circlip Pliers: 57001-144

5th gear [A] on the output shaft has three steel balls
• The
assembled into it for the positive neutral finder mechanism. Remove the 5th gear as follows.
○Set the output shaft in a vertical position holding the 3rd
gear [B].
○Spin the 5th gear quickly [C] and pull it off upward.

CRANKSHAFT/TRANSMISSION 9-43
Transmission
Transmission Shaft Assembly

molybdenum disulfide oil solution to the sliding sur• Apply
faces of the gears and shafts.
the gears and the gear bushings [A] with their holes
• Install
[B] aligned.

any circlips removed with new ones.
• Replace
Install
the
[A] so that the opening [B] of it is aligned
• with splinecirclips
grooves [C].
Install
the
circlips
• each gear side. so that the mark [D] on them faces to

drive shaft gears can be recognized by size: the gear
• The
with the smallest diameter is 1st gear, and the largest one

•
•
•
•
•

is 6th gear. Be sure that all parts are put back in the correct sequence and all circlips and washers are properly in
place.
Install the 3rd/4th gear onto the drive shaft with their oil
holes aligned.
Install the 5th and 6th gear bushings onto the drive shaft
with their oil holes aligned.
The output shaft gears can be recognized by size: the
gear with the largest diameter is 1st gear, and the smallest one is 6th gear. Be sure that all parts are put back
in the correct sequence and all circlips and washers are
properly in place.
Install the 6th gear onto the output shaft with their oil holes
aligned.
Install the 1st, 2nd and 3rd/4th gear bushings onto the
output shaft with their oil holes aligned.

9-44 CRANKSHAFT/TRANSMISSION
Transmission
the steel balls into the 5th gear holes in the output
• Fit
shaft.
5th Gear [A]
Output Shaft [B]
Steel Balls [C]

NOTICE
Do not apply grease to the balls to hold them in
place. This will cause the positive neutral finder
mechanism to malfunction.

○After assembling the 5th gear with steel balls in place on

•

the output shaft, check the ball-locking effect that the 5th
gear does not come out of the output shaft when moving
it up and down by hand.
Check that each gear spins or slides freely on the transmission shafts without binding after assembly.

CRANKSHAFT/TRANSMISSION 9-45
Transmission

1. 1st Gear
2. 2nd Gear
3. 3rd Gear
4. 4th Gear
5. 5th Gear
6. 6th (Top) Gear
7. Drive Shaft
8. Output Shaft
9. Circlip (Face the punch mark to the gear.)
10. Toothed Washer

11. Toothed Washer
12. Toothed Bushing, L = 15 mm (0.60 in.)
13. Toothed Washer
14. Circlip (Face the punch mark to the washer.)
15. Bushing, 31 mm (1.2 in.)
16. Toothed Bushing, L = 9.4 mm (0.37 in.)
17. Washer
18. Bushing, 25 mm (1.0 in.)

9-46 CRANKSHAFT/TRANSMISSION
Transmission
Shift Drum and Fork Removal

• Refer to the Transmission Assy Disassembly.
Shift Drum and Fork Installation

• Refer to the Transmission Assy Assembly.
Shift Drum Disassembly/Assembly

• Remove:
Shift Drum [A] (see Transmission Assy Disassembly)
•
•

Ball Bearing [B]
Press the ball bearing on the shift drum until it is bottomed.
Install the removed parts (see appropriate chapters).

Shift Fork Bending Inspection

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

the thickness of the shift fork ears [A], and mea• Measure
sure the width [B] of the gear grooves.
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:
5.7  6.0 mm (0.224  0.236 in.)
Service Limit: 5.6 mm (0.220 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.)

CRANKSHAFT/TRANSMISSION 9-47
Transmission
Shift Fork Guide Pin/Drum Groove Wear
Inspection

the diameter of each shift fork guide pin [A], and
• Measure
measure the width [B] of each shift drum groove.
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 (0.287 in.)

Gear Dog and Gear Dog Hole Damage Inspection

inspect the gear dogs [A] and gear dog holes [B].
• Visually
Replace any damaged gears or gears with excessively
worn dogs or dog holes.

9-48 CRANKSHAFT/TRANSMISSION
External Shift Mechanism
Shift Pedal Removal

the left lower fairing (see Lower Fairing Removal
• Remove
in the Frame chapter).
• Disconnect the quick shiftier sensor lead connector [A].

the quick shifter sensor lead [A] from the clamps
• Clear
[B].

• Remove:
Shift Lever Clamp Bolt [A]
Shift Lever [B]
Left Front Footpeg Bracket Bolts [C]
Left Front Footpeg Bracket [D] with Shift Pedal

• Remove:
Shift Pedal Mounting Bolt [A] and Washers
Shift Pedal [B]

Shift Pedal Installation

• Install:
Boll Joints [A] [B]

Quick Sifter Sensor [C]
Tie-Rod [D]
Tighten the shift rod adjusting locknuts [E] [F] temporarily.
○The boll joint [B] and locknut [F] have left-hand threads.

•

CRANKSHAFT/TRANSMISSION 9-49
External Shift Mechanism
grease to the sliding surface [A] on the shift pedal
• Apply
mounting bolt [B].
a non-permanent locking agent to the thread of the
• Apply
shift pedal mounting bolt.
the washers [C] as shown.
• Install
Tighten:
•
Torque - Shift Pedal Mounting Bolt: 25 N·m (2.5 kgf·m, 18
ft·lb)

installing the rubber damper [D], install it so that the
• When
chamfered side [E] faces inward.

• Install the left front footpeg bracket and tighten its bolts.
Torque - Front Footpeg Bracket Bolts: 25 N·m (2.5 kgf·m,
18 ft·lb)

the punch mark [A] on the shift shaft with the slit of
• Align
the shift lever and tighten the shift lever clamp bolt.
Torque - Shift Lever Clamp Bolt: 10 N·m (1.0 kgf·m, 89 in·lb)

the tie-rod [B] so that the engine mounting bolt and
• Turn
the shift pedal end are horizontal on same line [C].
• Tighten:
Torque - Shift Rod Adjusting Locknuts [D] [E]: 7.0 N·m (0.71
kgf·m, 62 in·lb)

○The locknut [E] has left-hand threads.

• Install the removed parts (see appropriate chapters).
External Shift Mechanism Removal

• Remove:
Shift Lever (see Shift Pedal Removal)

Oil Pump Drive Gear (see Oil Pump Drive Gear Removal/Installation in the Engine Lubrication System
chapter)
Circlip [A]
Washer [B]
Special Tool - Outside Circlip Pliers: 57001-144

• Remove:
Shift Shaft Assembly [A]
Washer [B]

○Take care not to drop the parts into the crankcase.

9-50 CRANKSHAFT/TRANSMISSION
External Shift Mechanism

• Remove:
Collar [A]
Shift Ratchet Assembly Holder Bolts [B]
Shift Ratchet Assembly [C] and Holder [D]

• Remove:
Gear Positioning Lever Bolt [A]
Gear Positioning Lever [B]
Washer and Spring [C]

External Shift Mechanism Installation

the gear positioning lever [A] as shown.
• Install
• Install:
Spring [B]

•

Washer [C]
Tighten:
Torque - Gear Positioning Lever Bolt [D]: 12 N·m (1.2 kgf·m,
106 in·lb)

• Assemble:
Ratchet [A]
Pawls [B]
Pins [C]
Springs [D]

the shift ratchet assembly [A] to the holder [B] as
• Install
shown.
the shift ratchet assembly to the shift drum cam [C].
•○Install
Fit the pawls [D] into the grooves [E].

CRANKSHAFT/TRANSMISSION 9-51
External Shift Mechanism
the shift ratchet assembly [A] as shown.
•○Set
Turn the shift ratchet assembly while pushing the pawls.
a non-permanent locking agent to the shift ratchet
• Apply
assembly holder bolts [B].
the shift ratchet assembly holder bolts temporar• Tighten
ily, and then tighten their bolts to the specified torque.

○Tighten the lower bolt first, and then tighten the upper one.
Torque - Shift Ratchet Assembly Holder Bolts: 15 N·m (1.5
kgf·m, 11 ft·lb)

the oil seal [A] with a new one.
• Replace
Apply
grease
lips of the oil seal.
• Apply engine oilto the
to the needle bearing [B].
•

• Install:
Collar [A]
•
•

Washer [B]
Shift Shaft Assembly [C]
Fit the hole [D] and the collar.
Fit the return spring [E] and the pin [F].

the circlip [A] with a new one.
• Replace
• Install:
Washer [B]
Circlip
Special Tool - Outside Circlip Pliers: 57001-144

○Fit the circlip into the groove of the shift shaft securely.

• Install the removed parts (see appropriate chapters).
External Shift Mechanism Inspection

the shift shaft [A] for any damage.
• Examine
If the shaft is bent, straighten or replace it.
If the serration [B] are damaged, replace the shaft.
If the spring [C] is damaged in any way, replace it.
If the shift mechanism arm [D] is damaged in any way,
replace the shaft.

9-52 CRANKSHAFT/TRANSMISSION
External Shift Mechanism
the shift ratchet assembly for any damage.
• Check
If the ratchet [A], pawls [B], pins [C] or springs [D] are
damaged in any way, replace them.

the return spring pin [A] is not loose.
• Check
If it is loose, unscrew it, apply a non-permanent locking
agent to the threads, and tighten it.
Torque - Shift Shaft Return Spring Pin: 29 N·m (3.0 kgf·m,
21 ft·lb)

the gear positioning lever [B] and spring [C] for
• Check
breaks or distortion.

•

If the lever or spring are damaged in any way, replace
them.
Visually inspect the shift drum cam [D].
If they are badly worn or if they show any damage, replace
it.

CRANKSHAFT/TRANSMISSION 9-53
Ball Bearing, Needle Bearing, and Oil Seal
Ball and Needle Bearing Replacement
NOTICE
Do not remove the ball or needle bearings unless it
is necessary. Removal may damage them.
a press or puller, remove the ball bearing and/or
• Using
needle bearings.

NOTE

○In the absence of the above mentioned tools, satisfactory results may be obtained by heating the case to approximately 93°C (200°F) max., and tapping the bearing
in or out.

NOTICE
Do not heat the case with a torch. This will warp the
case. Soak the case in oil and heat the oil.
a press and the bearing driver set [A], install the
• Using
new ball bearing until it stops at the bottom of its housing.

○The

new needle bearings must be pressed into the
crankcase so that the end is flush with the end of the
hole.
Special Tool - Bearing Driver Set: 57001-1129

Ball and Needle Bearing Wear Inspection
NOTICE
Do not remove the bearings for inspection. Removal may damage them.
the ball bearings.
•○Check
Since the ball bearings are made to extremely close tolerances, the wear must be judged by feel rather than measurement. Clean each bearing in a high flash-point solvent, dry it (do not spin the bearing while it is dry), and oil
it with engine oil.

○Spin [A] the bearing by hand to check its condition.
If the bearing is noisy, does not spin smoothly, or has any
rough spots, replace it.
Check the needle bearings.
○The rollers in a needle bearing normally wear very little,
and wear is difficult to measure. Instead of measuring,
inspect the bearing for abrasion, color change, or other
damage.
If there is any doubt as to the condition of a needle bearing, replace it.

•

Oil Seal Inspection

the oil seals.
• Inspect
Replace it if the lips are misshapen, discolored (indicating
that the rubber has deteriorated), hardened or otherwise
damaged.

WHEELS/TIRES 10-1

Wheels/Tires
Table of Contents
Exploded View........................................................................................................................
Specifications .........................................................................................................................
Special Tools ..........................................................................................................................
Wheels (Rims) ........................................................................................................................
Front Wheel Removal .......................................................................................................
Front Wheel Installation ....................................................................................................
Rear Wheel Removal........................................................................................................
Rear Wheel Installation.....................................................................................................
Wheel Inspection ..............................................................................................................
Axle Inspection..................................................................................................................
Balance Inspection............................................................................................................
Balance Adjustment ..........................................................................................................
Balance Weight Removal (ZX1000R/S)............................................................................
Balance Weight Installation (ZX1000R/S).........................................................................
Balance Weight Removal/Installation (ZX1000Z) .............................................................
Tires........................................................................................................................................
Air Pressure Inspection/Adjustment..................................................................................
Tire Inspection ..................................................................................................................
Tire Removal.....................................................................................................................
Tire Installation..................................................................................................................
Tire Repair ........................................................................................................................
Hub Bearing............................................................................................................................
Hub Bearing Removal (ZX1000R/S).................................................................................
Hub Bearing Installation (ZX1000R/S)..............................................................................
Hub Bearing Inspection.....................................................................................................
Hub Bearing Lubrication ...................................................................................................

10-2
10-6
10-7
10-8
10-8
10-8
10-10
10-10
10-12
10-12
10-13
10-13
10-13
10-13
10-15
10-16
10-16
10-16
10-16
10-16
10-18
10-19
10-19
10-19
10-19
10-20

10

10-2 WHEELS/TIRES
Exploded View
ZX1000R/S

WHEELS/TIRES 10-3
Exploded View
No.
1
2
3
4

Fastener
Front Axle Clamp Bolts
Front Axle Nut
Air Valve Nuts
Rear Axle Nut

G: Apply grease.
HG: Apply high-temperature grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts
S: Follow the specified tightening sequence.
WL: Apply soap and water solution or rubber lubricant.

N·m
20
130
4.5
130

Torque
kgf·m
2.0
13.3
0.46
13.3

ft·lb
15
95.9
40 in·lb
95.9

Remarks
S
L

10-4 WHEELS/TIRES
Exploded View
ZX1000Z

WHEELS/TIRES 10-5
Exploded View
No.
1