Secondary shaft gear installation

Aloha guys.

I did a search using word "Secondary shaft gear" but couldn't find what I was looking for. If there's a answer for this question, sorry. There wqas 8 pages but all had to do with removing, not install.

Anyway, my question is just that. Just how do you install the secondary shaft gear onto the shaft? This is what I'm talking about.

Below right is what I'm talking about. Top left with clutch mushroom installed.

From another angle.

I know there used to be a special tool for it, but I just need to know what's the thread size it use so I can create my own.

Huh?

How about installing the gear onto the shaft with the shaft outside the engine? A small hammer with block of wood maybe? You could prop up the shaft vertically over a wood work bench and then tap downward to install the gear.

Hard to tell from the pics, but it doesn't look like the splines mate correctly. Metal chips look suspicious too. Being forced unnecessarily?

Good Ridin'
slmjim & Z1BEBE

Nessism wrote: How about installing the gear onto the shaft with the shaft outside the engine? A small hammer with block of wood maybe? You could prop up the shaft vertically over a wood work bench and then tap downward to install the gear.

Unless you have or make a copy of the "special tool" Kawasaki used, you are going to have to do exactly what Nessism suggested.

Thanks guys.

Yeah, I thought about taking it out from the case, but the catch is, there's another rather large bearing on the other side, and this bearing is in the case rather deep. So this side looks easier, at least from what it looks like. I'll take picture later on to show it to you guys.

Oh, and don't worry about that metal shaving looking thing. The gear is just dirty. I already took it off to clean it, but it still refuse to go onto the shaft.

In the mean time, I'm still searching for the thread size. M10 is too small, M12 is too big. Just for the sake of it, I've tried 7/16x20 and only first few thread engage, so I'll try similar size SAE bolts to see if it fits.

It's not SAE. Most like a different thread pitch than the standard metric sizes.

Nessism wrote: It's not SAE. Most like a different thread pitch than the standard metric sizes.

But as I mentioned before, M10 are too small and M12 is too big so it's not thread pitch issue. However, I had 3/8 coarse thread bolt handy (I have 86' Monte Carlo SS and most bolts are metric, but some of the engine bolt/nut are SAE) and it's a lose fit, but it went as far as the bolt bottom out. And no, I wasn't forcing it, just hand tighten. Figure worth a try. Don't worry. I won't force it in (sounds kinky, huh?)

Ojisan rider wrote:

Nessism wrote: It's not SAE. Most like a different thread pitch than the standard metric sizes.

But as I mentioned before, M10 are too small and M12 is too big so it's not thread pitch issue. However, I had 3/8 coarse thread bolt handy (I have 86' Monte Carlo SS and most bolts are metric, but some of the engine bolt/nut are SAE) and it's a lose fit, but it went as far as the bolt bottom out. And no, I wasn't forcing it, just hand tighten. Figure worth a try. Don't worry. I won't force it in (sounds kinky, huh?)

The standard pitch for a 10mm bolt is 1.5 threads/mm and fine is 1.25. I suspect the hole is threaded with fine pitch metric threads.