Rotor removal requires a puller such as
the one described in the procedure below.
Don't pry or hammer on the rotor itself:
Damage is sure to result and you may
destroy the rotor magnetism.
1. Remove the rotor bolt (B, Figure 29).
To remove the rotor without
tool, you can lock the engine by shijiing
the transmission into gear and stepping
on the brake pedal or by removing the
clutch c o w and styfing a copper penny
or clean rag, folded several times,
between the secondarv gear and the
clutch ring gear.
2. Loosen the rotor. A simple long bolt with 10
mm threads to match the large threaded rotor
hole will work. Your Kawasaki dealer has a
special tool to do the job. Screw in the bolt to
pull the rotor off. You may have to alternate
tapping on the puller bolt sharply with a
hammer and tightening the bolt some more,
but don't hit the rotor.
3. Remove the puller and the rotor.
4. To install, reverse the removal steps. Note
a. Inspect the inside ofthe rotor carefully for
any bits of metal or small parts that may
have been picked up by the rotor
magnets. R e m o v e them to prevent
damage when the engine starts.
b. Use a solvent to clean any oil from the
tapered crankshaft end.
O C ~ O I J
c. Rotor bolt torque is specified in Table 2.
Hold the rotor from turning using the
same method as during removal.
The starting system consists of the starter
motor. starter clutch, starter solenoid, starter
lockout switch and the starter button. Figure
30 is a schematic diagram of the starting
When the clutch lever is pulled and the
starter button is pressed, it engages the solenoid
switch that closes the circuit. Then electricity
flows from the battery to the starter motor.
The starter motor is a 12-volt DC motor
geared to the secondary shaft through an idler
gear and the clutch gear on the secondary shaft.
The starter motor is connected mechanically to
the crankshaft and can rotate it when the
engine is not running. The starter clutch
(between t h e idler a n d the clutch gear)
uncouples the clutch gear from the secondary
shaft when the engine is running.
1. Disconnect the battery negative
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