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Magneto Cover Assembly; Magneto Flywheel Removal; Magneto Flywheel Installation - Kawasaki KLX110 Service Manual

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Flywheel Magneto

Magneto Cover Assembly

Run the magneto lead [A] as shown.
Torque:
Plate Screws [B]: 2.9 N
Exciter Coil Mounting Screws [C]: 5.2 N
Pickup Coil Mounting Screws [D]: 2.9 N

Magneto Flywheel Removal

Remove the magneto cover (see this chapter).
Loosen the front footpeg assembly.
Hold the flywheel steady with the flywheel holder [A] and remove the
flywheel nut [B].
Special Tool -
Flywheel Holder: 57001–1313
Thread the flywheel puller [A] and rotor puller [B] onto the flywheel
[C].
Holding the flywheel puller, turn the rotor puller until the flywheel is
forced off the end of the crankshaft.
Using the flywheel and rotor pullers, remove the magneto flywheel.
Special Tools - Rotor Puller, M16/M18/M20/M22 x 1.5: 57001–1216
Flywheel Puller, M28
If the rotor is difficult to remove, turn the puller shaft using
a wrench while tapping the head of the puller shaft with a
hammer. Do not attempt to strike the grab bar or the alternator
rotor itself. Striking the bar or the rotor can cause the bar to
bend or the magnets to lose their magnetism.

Magneto Flywheel Installation

Using a high-flash-point solvent, clean off the any oil or dirt that may
be on the crankshaft tapered portion [A] and flywheel tapered portion
[B].
Fit the woodruff key [C] securely in the slot of the crankshaft before
installing the flywheel on the crankshaft.
Tighten the flywheel nut while holding the flywheel steadily with the
flywheel holder.
Torque -
Magneto Flywheel Nut: 41.5 N
Special Tools - Flywheel Holder: 57001–1313
m (0.3 kgf
m, 26 in
lb)
1
1
1
m (0.53 kgf
1
m (0.3 kgf
m, 26 in
1
1
1.0: 57001–1471
2
CAUTION
m (4.25 kgf
1
1
ELECTRICAL SYSTEM 14-9
m, 46 in
lb)
1
1
lb)
1
m, 30.6 ft
lb)
1

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