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Table of Contents
78
DISASSEMBLY-ENGINE REMOVED
•Apply
a non-permanent
locking agent
to
the
starter
motor mounting
bolts,
and
tighten the bolts
to 1.0
kg-m
(87 in-lbs)
of torque.
•Apply
a smal
l
amount of molybdenum disu lfide grease
in
the bush in the
starter
drive gear.
Put the
starter
drive gear
onto
the crankshaft with the protruding side
facing outward. Then,
put on the copper washer.
•Using a high
flash-point solvent,
clean
off any oil or
dirt that ma
y
be
on
the
crankshaft taper or rotor
hub.
•Fit
the
wood ruff key into
the
groove on
the
crank-
shaft.
A. Starter Drive
Gear
C. Key
B. Copper Washer
•Apply
engine
oil
to
the
starter drive
gear boss.
•Make sure that
the ro llers,
spring caps,
and springs are
properly fitted
in the
starter clutch, and
fit the
rotor
and
starter
clutch
assembly on
the crankshaft.
Turn·
ing the starter drive gear clockwise
during this
proce·
dure
wi
ll
help
the
rol lers in
the clutch
fit
properly.
•Tighten the
roto
r
bolt
to
7.0
kg-m
(5
1
ft-lbs)
of
to
rq
ue,
using
the fl ywheel
hold er
(special
tool)
to hold
the
crankshaft
steady.
•Apply
a
small amount of molybdenum
disulfide
grease
to
the shaft
portion
of the
starter
idler gears.
Fit the
starter idler
gears
so t hat
the
gears mesh with
the
starter drive gear and starter
pinion.
A.
Starter Drive
Gear
C. Starter
Pinion
B.
Starter
Idler
Gears
•Fit the woodruff key into the groove on
t
he right
side
of
the
crankshaft.
•Fit
the
primary gear on the crankshaft with the
pro-
truding side facing inward.
•Put on the
toothed
washer with
the tooth fi
tted
into
the
groove in
t he
primary
gear. Screw
on t
he
primary
gear
nut.
Highten the primary gear
nut
to 7.0 kg-m (51
f t-lbs)
of torque, using
the flywheel holder
(special
tool}
to
hold
the crankshaft
steady.
•Bend
part
of the toothed washer over the side of the
primary
gear nut.
•Smear a smal
l
amount of molybdenum disulfide grease
on
t
he shaft
portion of the oil pump drive
gears.
Fit
the oil pump drive gears so that
t
he
gears mesh with
the
primary gear
and
oi
l
pump gear.
A. Primary Gear
C. Oil Pump Gear
B. Oil Pump Drive Gears
•Make sure that
the return
spring pin is
not
loose.
If
it is
loose,
remove it,
apply a non-permanent
locking
agent
to the
threads,
and
install
it.
•Fit the
coll
ar and
retu
rn
spring on
the
shi
ft
shaft.
Make sure that the arm spring
is
installed
on
L
he
two arms.

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   Also See for Kawasaki Z250 1981

This manual is also suitable for:

Kz350 1981

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