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Since most bearings are installed with an
interference fit, if possible heat the part in an
oven to about 212"
to aid bearing
removal and installation.
Heating should be done in an oven and
not with a torch; it's hard to get uniform
heating with a torch, and the likelihood
of warping the case is great.
If the bearings are hard to remove, they can
be gently tapped out with a socket or piece of
pipe the same size as the bearing outer race.
Install the new bearing while the case is still
hot. The marked side of a needle bearing faces
out. If necessary, freeze the bearing before
installing, to provide extra clearance.
Make sure that the bearings are not cocked in
the hole and that they are seated properly.
The alternator-side secondary shaft
bearing should he 0 . 4 2 - 0 . 4 4 i n .
inside the outer surface
of the crankcase boss.
If bearings are hard to remove or install,
don't take a chance on expensive case damage.
Have the work done by a Kawasaki dealer or
competent machine shop.
Refer to Figure 123. The secondary shaft is
an intermediate shaft driven by a chain from
the crankshaft. The secondary shaft transmits
power to the clutch ring gear and it turns the
crankshaft when driven by the electric starter.
The driven sprocket on the secondary shaft
has an internal rubber damper to smooth
engine torque peaks. The starter drive clutch is
mounted on the sprocket damper.
Secondary shaft removal is part of the
crankcase separation procedure. This section
describes shaft and starter clutch disassembly
and inspection.
Primary Chain Inspection
The primary chain can be inspected after
removing the oil pan. See
O i l
Pan Removal
this chapter. The primary chain should be
replaced when it has more than 0.98 in. (25
mm) of up and down slack (Figure 117).
Inspect the secondary shaft sprocket carefully
when you replace the chain. It is likely that
both will need to be replaced at the same time.
1. See Figure 123. Pull the starter clutch gear
out of the starter clutch.
2. Remove the 3 rollers, spring caps and
springs from the clutch (Figure 124).
Remove the
Allen screws that mount the
clutch body to the rotor.
4. T h e secondary shaft internal rubber
dampers can be replaced after removing the
circlip on the end of the driven sprocket.
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