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Kawasaki Z250 1981 Service Manual Page 78

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72 DISASSEMBLY-ENGINE REMOVED
•Connect
the
starter motor lead to
the
starter
motor
terminal.
Slide on the
rubber
boot.
•Install
the
rea
r brake
light
switch
and
bolt.
Hook
t
he
spring
on
to the
switch.
•Connect
the tachometer cable,
and
tighten
the
cable
nut
using pliers.
•Install
the
drive chain (Pg. 97).
•Connect
the alternator leads and
neutral
indicator
switch
lead.
(E~:iI§J
: ~ ~: n
t~~eex~~:se s~~~
0
on
9
u~~ l:~~s :~;
crankcase so that the leads cannot contact the drive
chain.
A.
Alternator
Leads
B. Neutral Switch Lead
•Route the
clutch
cable
between
the left
side of the
engine and
the
frame.
Feed the clutch
cab le
through
the engine sprocket
cover
and spring,
and
fi
t the
t
ip
of the
inner
cable into
the
clutch
release
lever.
~Using a
new cotter pin, secure
the
cable tip
to the
rel
ease lever.
•Check that the engine sprocket cover knock
pins (2)
and clutch push
rod
arc
in
place,
and fit
the
engine
sprocket cover. Tighten the mounting screws.
•Install
the
left
footpeg, bolt, and
lockwasher.
•Mount the shift pedal
with
the
front of
the
pedal
slightly
below
tire
shaft.
Insert
the clamp
bolt and
tighten
it securely.
•Instal
l
the carburetors
(Pg.
39).
•Instal
l
the
capacitors, mounting screws
(2),
and
lock·
washers
(2).
Connect the
leads from
the capacitors,
contact breakers,
and ignition coils.
•Install the horn, bolts,
and lockwashers. Connect the
ho
rn
leads.
•Instal
l
the fuel tank
(Pg.
39).
Fill
the
engine
with
oil.
•Adju
st
the clutch
(Pg.
20}.
•Adjust
the
carburetors
(Pg.
18}.
•Adjust
the
drive chain (Pg. 24).
•Ad just the rear
brake
(Pg. 25).
•Adjust
the rear
brake light
switch
(Pg. 26).
•Screw
the
spark
plugs
·
into
the cylinder
head,
and
tighten
them
to
2.0 kg-m
(14.5
ft-lbs}
of
torque.
Con-
nect
the
spark
plug
leads.
•If the
engine
was
disassembled, check the dynamic
ignition
tim
ing
(Pg.
15).
•Adjust
the
idle
speed
(Pg.
19).
CRANKCASE
SPLIT
Disassembly:
•Remove
the engine (Pg.
70).
•Remove the
breather
cover
and gasket.
•Set
the
engine
on
a clean
surface
or, preferably on
an
engine stand (special
tool).
A. Engine Stand
(57001-900)
•Remove
the bolt
and tachometer
pinion
holder
stop.
Pull out
the
tachometer pinion holder and
pinion.
A. Bolt
B. Stop
•Remove the
valve adjusting caps (4).
•Remove
the alternator
cover.
•Remove
the
contact
breaker cover and gasket.
•Remove
the
mounting
screws (2), and
take
contact
breaker mounting plate.
off
the

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Kz350 1981

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