All may be revealed in that something is not operating correctly. Operate the gears manually up through the box until you get to 5th, you may need the bike up on a stand and rock the rear wheel to ease selection,and see whats wrong. If you have the knowledge to remove the right hand outer case you will see the linkage and shifter drum end behind the clutch drum. The shift linkage pulls the drum around by these pins as you change gear. It gives a friendly little shake every now and then just to remind you its there lol. The 2.5 tends to idle a little rough from what i have noticed. Go to the gearbox selector drum and the gear change linkage and you will see on the right hand end of the shifter drum is a star looking piece with small pins sticking out. No programming with the intake could be the cause of the CEL, lean engine code.
O2j 5th gear fix series#
When you take the outer case off be aware of any small part that may be lying in the bottom that may give a clue? If you go to this website, CMSNL and select Kawasaki then drill down through the various models 'till you come to 6R, you will be confronted with a series of exploded parts views. If the shift drum is damaged or the fault is not obvious seek good help as to the best way forward. The shift linkage pulls the drum around by these pins as you change gear. First 6th goes in with it’s drive gear then the synchronising hub, another needle bearing, 5th gear, spindle, 5th drive gear, and finally the bolts torqued to 120Nm with a stronger Loctite. 02A the MK3/Corrado type, 5h1te & characterised by a black plastic top hat.
Im probably replacing the transmission in my wagon in the next few months as its finally showing the consequences of 322K of hard use, and most likely wont change the gearing in the new transmission. Yes, 02J is the MK4 type much cleaner & simpler in appearance, uses different cable (ends) and the cables mount to the box at different angles. Go to the gearbox selector drum and the gear change linkage and you will see on the right hand end of the shifter drum is a star looking piece with small pins sticking out. 71 5th in my wagon and B4, but recently drove my sons car with stock gearing. If you go to this website, CMSNL and select Kawasaki then drill down through the various models 'till you come to 6R, you will be confronted with a series of exploded parts views.
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