Kawasaki J300 - Service manual > Final Drive

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G: Apply grease.
R: Replacement Parts

Specifications

Special Tools

Bearing Driver Set: 57001-1129

Oil Seal & Bearing Remover: 57001-Y024

Final Gear Case

Final Gear Case Disassembly

NOTE

• Do not remove the final gear case cover except for necessary part replacement.
• When replacing the drive shaft, also replace the bearing and oil seal.

 

• Remove:
  Rear Wheel (see Rear Wheel Removal in the Wheels/Tires chapter)
  Clutch/Driven Pulley Assembly (see Clutch/Driven Pulley Removal in the Converter System chapter)
• Drain the final gear case oil (see Final Gear Case Oil Change in the Periodic Maintenance chapter).
• Remove:
  Final Gear Case Cover Bolts [A]
  Final Gear Case Cover [B] and Gasket

• Remove:
  Final Shaft [A]
  Countershaft [B]

• Using a press [A], remove the drive shaft [B] from the final gear case cover [C] if necessary.

Final Gear Case Assembly

• When the drive shaft is removed, replace the drive shaft bearing and oil seal (see Final Reduction Bearing Replacement).
  • Using a press, install the drive shaft to the final gear case cover.
• Replace the oil seal [A] on the left crankcase with a new one.
• Apply grease to the oil seal lips, and install the oil seal to the left crankcase.

• Install:
  Countershaft [A]
  Final Shaft [B]
• Replace the final gear case cover gasket with a new one. -Install the dowel pins [C] and new gasket are in place on the left crankcase.
• Install the final gear case cover and tighten them bolt.

  Torque - Final Gear Case Cover Bolts: 20 N*m (2.0 kgf*m, 15 ft*lb)

• Fill the final gear case with final gear case oil (see Final Gear Case Oil Change in the Periodic Maintenance chapter).
• Install the removed parts (see appropriate chapters).

Final Gear Case Inspection

• Disassembly the final gear case (see Final Gear Case Disassembly).
• Inspect the countershaft [A] and gears [B] for wear or damage.

  If there is any damage, replace it.

• Inspect the final shaft [A] and gear [B] for wear or damage.

  If there is any damage, replace it.

• Inspect the drive shaft [A] and gear [B] for wear or damage.

  If there is any damage, replace it.

NOTE

• When replacing the drive shaft, also replace the bearing and oil seal.

 

• Inspect the bearings [C] for excessive play or noise.

  If there is any damage, replace it (see Final Gear Bearing Replacement).

Final Gear Bearing Replacement

• Disassembly the final gear case (see Final Gear Case Disassembly).
• Remove the bearings.

  Special Tool - Oil Seal & Bearing Remover [A]: 57001-Y024

  • For removing the final shaft bearing and the drive shaft bearing, use the bearing driver set.

  Special Tool - Bearing Driver Set: 57001-1129

• Replace the bearings with new ones.
• Press the bearings until they are bottomed.

  Special Tool - Bearing Driver Set [A]: 57001-1129

See also: