PROJECT H2 Service Data: Tranny Kit Manual
Date: 2006-08-21
Related Pages:
Contents:
PROJECT H2 ⁄ Sy-Tech™ Kawasaki 750H2 and 500H1 Series Transmission Kit Manual
About this Tranny Kit:
To the Buyer:
WARNING: DO NOT ATTEMPT TO ASSEMBLE THIS TRANNY KIT BASED ON THE INFORMATION IN THIS MANUAL. THIS TRANNY KIT SHOULD BE ASSEMBLED AND INSTALLED BY A LICENSED MECHANIC EXPERIENCED IN KAWASAKI H2'S.
To the Mechanic:
1. Please read the manual carefully before proceeding with assembly.
2. What is referred to as the "Standard Setting" in this manual
should not be confused with the standard setting taken from a Kawasaki manual.
The standard setting is solely for a Project H2 tranny kit. Parts for this
tranny kit were designed based on a new and a used crankcase in good condition.
When properly assembled, this tranny kit is compatible with a Kawasaki H2
stock engine.
3. This manual provides general information regarding the H2 transmission
and is only to be used as a reference for transmission adjustment. It does
not deal with transmission problems resulting caused by other parts
Specifications:
PROJECT H2 Transmission kit description
- Type: 5-speed, constant mesh, return shift
- Transmission oil: 2cycle gear oil
- Oil capacity: 1.5 to1.7 liters
| Type | H2 SPR | H2 Racing | H1 Tranny |
|---|---|---|---|
| 1st | 13 - 26 (2.00) | 13 - 26 (2.00) | 15 - 33 (2.20) |
| 2nd | 20 - 28 (1.40) | 17 - 22 (1.29) | 20 - 28 (1.40) |
| 3rd | 20 - 21 (1.05) | 21 - 22 (1.04) | 23 - 25 (1.09) |
| 4th | 20 - 18 (0.90) | 20 - 18 (0.90) | 25 - 23 (0.92) |
| 5th | 21 - 17 (0.81) | 23 - 19 (0.83) | 26 - 21 (0.80) |
H2 Transmission Kit Parts Data:
| No. | Name | Q.TY | Note |
|---|---|---|---|
| 1. | Ball bearing, #6305N | 1 | 6305N C3 |
| 2. | Shaft, Drive | 1 | 13T |
| 3. | Top gear, Drive shaft | 1 | 21T |
| 4. | 3rd gear, Drive shaft | 1 | 20T |
| 5. | 4th gear, Drive shaft | 1 | 20T |
| 6. | 4th gear, Drive shaft | 1 | 20T |
| 7. | Shaft, Output | 1 | - |
| 8. | Ball bearing, #6005 | 1 | 6005 C3 |
| 9. | Collar | 1 | - |
| 10. | Washer, Thrust t = 0.5mm | 5 | 1 included for adjustment |
| 11. | 2nd gear, Output shaft | 1 | 28T |
| 12. | 4th gear, Output shaft | 1 | 18T |
| 13. | 3rd gear, Output shaft | 1 | 21T |
| 14. | Top gear, Output shaft | 1 | 17T |
| 15. | 1st gear, Output shaft | 1 | 26T |
| 16. | Ball bearing, #6205N | 1 | 6205NX3 C3 |
| 17. | Spacer, Engine sprocket | 1 | - |
| 18. | O ring | 1 | - |
| 19. | Washer (Toothed) | 1 | - |
| 20. | Washer, Thrust t = 1.0 | 5 | 2 included for adjustment |
| 21. | Circlip, 24mm | 5 | - |
| 22. | Washer, Thrust t = 1.0mm | 3 | Steel |
| 23. | Washer, Thrust t = 1.0mm | 2 | PBC |
| 24. | Washer, Thrust t = 0.5mm | 2 | Steel |
| 25. | Needle bearing | 2 | - |
| 26. | Circlip | 2 | - |
Inspect your crankcase and change mechanism prior to installing the transmission.
Check your crankcase carefully to see that there are no cracks or signs
of wear in the bearing holders, and that the stud bolts are not bent.
Check your change mechanism carefully, and replace the return spring if
it is weak. Make sure the change lever is not loose, the hook is not worn
or bent and the change lever spring is not out of tolerance. It is hard
to detect, but the change lever spring weakens quickly.
Check your shift drum to see that the screws on the gear change drum positioning
plate have not loosened, shift drum pins are not bent, and the gear change
drum plate has not warped out of shape.
Check your shift forks to see that they are not loose on the change drum
and the prongs are not worn out of tolerance. If there is a lot of play
on the drum, the shift fork will not follow their slots properly in order
to slide the gears into various configurations, or it may get stuck. As
the prongs near or pass tolerance limits, an increase in the stroke will
become necessary when shifting, and it may be difficult to change gears
properly. The dogs will not be aligned properly, adding to wear, and resulting
in the gears failing to position properly, or jumping out of mesh while
running.
Transmission Assembly:
Assembly
is made to be done in the same manner as a genuine transmission. Warnings
specific to Project H2's Tranny Kit are listed below.
1. TK001 Ball bearing
The input shaft and the TK001 were designed to be installed with heat. Warm
up the ball bearing with a heat gun before installing it in the shaft. Do
not pound the ball bearing to force it in.
Although tolerance is as close to 0 as possible, there may be instances
where tolerance is higher. If you feel the bearing has too much play, use
Loctite 243 (medium strength) to resolve the situation.
2. TKO19 Lock Washer
Important: make sure the toothed washer is used on the output third gear.
3. 3rd Gear
If the third gear has too much play, you may use a TK024 (0.5mm washer)
between the third gear (TK013) and TK019 to compensate. This should only
be done at the discretion of the mechanic.
Shift Fork Inspection :
Measure the clearance by inserting a thickness gauge between the shift
fork and the prong and the walls of the groove. This clearance check should
be done on the short prong. 0.05 - 0.25mm clearance is standard, 0.6mm is
the service limit. If the wear is nearing 0.6mm, it can cause the gears
to fail to position properly, or jump out of mesh while running.
Shift forks that are worn or have become discolored from over heating are
dangerous. In the worst case scenario, the prongs could break, so it is
necessary to change discolored shift forks.
Fitting:
General H series Transmission Problems:
There are problems of gear engagement resulting from excessive play in the
stationary gears on both the drive and output shaft. This can be caused
by a distortion of the crankcase or the condition of the change mechanism.
These problems can occur even with new a crankcase, and most of the crankcases
have been in use for about 30 years. Problems with the crankcase and the
overall condition of the bike will lead to various transmission problems.
Corrective Action for Transmission:
This tranny kit manual includes corrective action using additional shims
on both the drive and output shaft to deal with gear engagement trouble
that can occur. These measures can also be used if the transmission jumps
out of gear or does not operate properly. Shim adjustment must be done according
to the individual needs and state of each engine. *In some cases, further
corrective action other than what is listed in this manual may be necessary.
All clearances are checked with the transmission in neutral.
A. CORRECTIVE ACTION FOR 4Th GEAR:
1. To achieve the standard setting for this tranny kit insert a 0.5mm shim (P/N TK010) between second gear and fourth gear. This shim will properly align the shaft in the crankcase.
2. If fourth gear dogs hit third gear dogs after adding the 0.5mm shim (P/N TK010), then take it back out and insert it between fourth gear and the existing 1.0mm shim. This keeps the sloppiness out of the gear without forcing the dogs together.
B. CORRECTIVE ACTION FOR 5TH GEAR:
To eliminate jumping out fifth gear, measure the clearance between fifth and third gear dogs on the drive shaft. To achieve the standard setting for this tranny kit, insert a 1.0mm shim (P/N TK019) between fifth gear and the circlip. If the clearance is over 2.0mm, remove the 1.0mm shim (P/N TK019) between fifth gear and the circlip, and add a 0.5mm shim (P/N TK010) on either side of fifth gear.
| Problem | Check Clearance | Take Out | Insert |
|---|---|---|---|
| Jumping out of 5th gear. | Check clearance between 5th and 3rd gear dogs on drive shaft. | If clearance is greater than 2.0mm take out 1.0mm shim between 5th and circlip. | Insert 0.5mm shim (P/N TK010) on either side of 5th gear on the drive shaft. |
| If less than 2.0mm leave shim where it is. | ------- |
C. CORRECTIVE ACTION FOR 2ND GEAR:
To achieve the standard setting and eliminate play at second gear on the output shaft, install a 0.5mm shim (P/N TK010) on both sides of the gear. This moves the gear slightly closer to the fourth gear slider as well as reducing play. If the dogs on fourth gear hit second gear with the standard setting, remove both shims and add a 1.0mm shim (P/N TK019) between second gear and the circlip. This will keep the dogs from hitting, while eliminating play at second gear.
| Problem | Ref. | Take Out | Insert |
|---|---|---|---|
| 4th gear dogs hit 2nd gear. | 1 | Take out both shims on 2nd gear. | Add 1.0mm shim (P/N TK019) between 2nd gear and circlip on output shaft. |
| 4th gear dogs hit 2nd gear. | 2 | Take out 0.5mm shim (4th gear side) | Add 1.0mm shim (P/N TK019) between 2nd gear and circlip on output shaft. |
