Service Manual (KLZ1000C) — page 300 of 762

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9-36 CRANKSHAFT/TRANSMISSION
Transmission

• The  drive shaft gears can be recognized by size: the gear
  with the smallest diameter is 1st gear, and the largest one
    is 6th gear. Be sure that all parts are put back in the cor-
    rect 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 small-
    est 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 2nd and 3rd/4th gear bushings onto the output
    shaft with their oil holes aligned.

                               NOTE
    ○When the toothed washers are assembled onto the
     each shaft, note the following.
    ○Align the punch marks [A] of the toothed washers (only
     on drive shaft).
    ○When the tangs [B] of the toothed washer shall be as-
     sembled, they should be installed into the notch [C] of
     the toothed washer (see Page 9-38).

• Fit the steel balls into the 5th gear holes in the output
  shaft, aligning the holes as shown.
     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 doesn’t come out of the output shaft when moving it
    up and down by hand.
•   Check that each gear spins or slides freely on the trans-
    mission shafts without binding after assembly.