Stator Coil Installation
Route the leads according to the Cable, Wire, and Hose
Routing section in the Appendix chapter.
Apply a non-permanent locking agent to the stator coil
Install the stator and tighten the stator coil bolts.
Torque - Stator Coil Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
Install the crankshaft sensor [A] and wiring holder [B].
Run the magneto leads under the sensor, and hold the
guide [C] of the holder.
Torque - Crankshaft Sensor Bolts: 7.0 N·m (0.71 kgf·m, 62
Apply silicone sealant around the circumference of the
wiring grommet [D].
Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004
Set the stator wiring grommet securely in the notch.
Install the magneto cover (see Magneto Cover Installa-
There are three types of magneto problems: short, open
(lead burned out), or loss in flywheel. A short or open in one
of the coil leads will result in either a low output, or no output
at all. A loss in flywheel, which may be caused by dropping
or hitting the flywheel by leaving it near an electromagnetic
field, or just by aging, will result in low output.
Check the magneto output voltage, do the following pro-
Remove the left radiator shroud.
Connect the hand tester [A] to the connector [B] as shown
in the table 1, using the needle adapter set [C].
Start the engine.
Run it at the rpm given in the table 1.
Note the voltage readings (total 2 measurements).
Special Tools - Hand Tester: 57001-1394
Needle Adapter Set: 57001-1457
Table 1 Magneto Output Voltage
Tester (+) to
50 V AC
One yellow lead
If the output voltage shows the value in the table, the mag-
neto operates properly.
If the output voltage shows a much lower reading than that
given in the table it indicates that the magneto is defective.
To check the stator coil resistance as follows.
Stop the engine.
Disconnect the connector.
Connect the hand tester as shown in the table 2.
Note the readings (total 2 measurement).
Tester (–) to
ELECTRICAL SYSTEM 16-15
@4 000 rpm
37 V or more