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58 DISASSEMBLY-ENGINE INSTALLED
lnstal
lat ion:
•Using a high flash-point solvent, clean off any oil or
dirt that may be on the crankshaft
taper
or
rotor
hub.
•Apply engine oil
to
the starter drive gear boss.
•Make sure that the woodruff
key
is properly fitted
and
that
the
copper
washer
is attached
on the crank-
shaft, and fit
the
rotor and starter clutch assembly
on the crankshaft.
Turning
the
starter drive gear
clockwise
during
this
procedure will help the rollers
in
the
clutch
fit
properly
.
A.
Starter Drive Gear
•Tighten
the
rotor bolt to 7
kg-m (51
ft-lbs)
of
torq
ue,
using
the
flywheel
holde
r
(special
tool)
to hold
the
crankshaft steady.
•Make sure that
the
knock
pins (2) are
in
place,
and
fit
the
left engine cover using a new gasket.
Tighte
n
the
screws
(9).
•Connect
the
alternator
leads (2)
.
•Install the engine sprocket cover
(Pg.
54).
•Check
the
clutch
(Pg.
20), and adjust
if
necessary.
•Check the oil
level
(Pg.
21
),
and add more
if nec-
essary
..
Disassembly:
•Remove the rollers, springs, and
spring
cap (3
ea)
from the starter motor clutch.
A.
Starter
Motor
Clutch
C.
Spring
Cap
B.
Roller
D. Spring
•Using the flywheel
holder (special tool) to
hold the
rotor steady,
remove
the Allen bolts
(3)
to separate
the starter motor clutch
from the
rotor.
A. Flywheel Holder (57001-308)
Assembly Note:
•Apply a
no n-permanent
locking agent to the
star
ter
motor
clutch
Allen bolts
(3},
and tighten the bolts
to
3.5 kg-m
(25
ft-lbs) of
torque.
ST ARTER MOTOR
Removal:
•Remove the engine sprocket cover (Pg.
54).
Removal
of the clutch cable
from the
cover
is
not
necessary.
•Disconnect the alternator leads.
•Place an oil
pan
beneath
the
left
engine cover.
•Remove the screws
(9}, and
pull
off the left engine
cover
and gasket.
•Slide off the rubber
boot,
and
loosen the
starter
motor terminal nut.
A.
Rubber Boot
•Remove
the
camshaft chain tensioner c.tp.
•Loosen
the
c.trburetor
holder
clamp screws,
and
slide
the
carbu
re
tors
off toward the
air
cleaner
housing.
•Remove the starter motor
re
tain
ing bolts (2).
•Pry
the
starter
motor
loose
from
the
cran
kcase with
a screwdriver, and slide
it
off.

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   Also See for Kawasaki Z250 1981

This manual is also suitable for:

Kz350 1981

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