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108 DISASSEMBLY-CHASSIS
(19) and
lower steel ball
s (19).
All the steel balls
are
same
size.
A. Steel
Balls
•Put on the upper inner race and steering
stem
cap.
Insert
the
steering stem
into
the head pipe, and
tighten
the steering stem
locknut
to 2.0 kg-rn
(14.5 ft-lbs)
of
torque.
•Run
each
fork tube
up
through its
clamp in
the stern
base.
Temporarily
tighten the
lower clamp
bolts
to
hold the
fork
legs
in
place
with the
legs
protruding
about
170
mm
above
the
steering
stem base.
•Place the throttle
cables
and
right
switch
housing
harness between
the
head pipe
and
the right fork
tube.
Place
the left
switch
housing
harness and main
wiring harness
between
the
head pipe and
the left
fork
tLtbe.
•Install
the
headlight bracket
between the
front
fork
legs.
A.
Headlight Bracket
B.
Wire Harness
•Slide
the right side
of the
handlebar
through
the
right
switch
housing, and into
the
throttle grip
assembly.
•F it
the stem
head
and
handlebar
on
to
the
steering
stem and
fork
tubes.
Pu
t
on
the
lockwasher
and
flat
washer
and screw in
the
stem
head
bolt.
•For each
fork
leg, loosen the
lower
clamp,
and align
the upper end of the
front
fork inner tube
with
the
upper su
rface
of
the
stem head
.
Tighten
the
upper
clamp
bolt
to 1.8
kg-m (13.0
ft
-lbs)
of torque.
A. Inner Tube Upper End
•Tighten
the
stem head bolt
to
4.0 kg-m
(29
ft·lbs)
of torque
and
the
stem
head
clamp
bolt
to
1.8
kg·m
(13.0
ft-lbs)
of torque.
•Tighten the
front
fork
lower
clamp
bolts
to 2.5
kg·m
(18 ft-I
bs)
of
torque.
•Put together
the
right
switch housing and tighten its
screws.
The
upper
half
of
the housing has
a small
projection which fits
into a hole
in
the
handlebar.
The front
switch
housing
screw is
longer
than
the
rear screw.
A. Porjection
B. Hole
•Position
the left
switch
housing in place, and tighten
its screws.
The
front screw is
longer
than
the rear
screw.
•Strap both the
left and right
switch
housing wiring
harness onto the
handlebar.
•Mount the instrument
panel onto
the
stem head so
that
the
wire
harnesses from
both
switch housings
and
front
brake
light
switch
lead
run between the
meters and
the
stem
head.
Install
the
nuts,
lock-
washers,
and
flat washers under the instrument
panel.
•Run the upper end
of
the
clutch
cable
between
the
speedometer
and the
stern head, and
connect it to
the clutch lever.
•Instal
l
the master
cylinder
on
the han
dlebar
with
the
small projection on
the
clamp
facing the
throttle
grip
(Fig.
G20 on
Pg. 95).
lighten
first
the upper
clamp
bolt
and
then the lower bolt, to
0.8
kg-m (69
in-lbs)
of
torque. Each
clamp bolt has
a flat
washer.

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   Also See for Kawasaki Z250 1981

This manual is also suitable for:

Kz350 1981

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