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90 DISASSEMBLY-CHASSIS
Pull
out the
speedometer gear
~
t
-
lf
it
is necessary to remove
the
speedometer cable
bushing
ff
or speedometer
pinion
®
,
first
drill
the
housi
ng
through
the pin
(6
)
using a 1
mm
drill bit.
Drill
the housing
from the gear side using
a
2 mm
drill
bit.
Using
a
suitable
tool, tap out
the
pin,
and then
pull
out the
speedometer
cable
bushing
and
pinion.
NOTE
:
It
is
recommended
that
the
speedometer
gear housing is
replaced
as
an
assembly rather than
repairing
the components.
Assembly Notes:
1.
Replace
the
grease seal with
a new
one. Apply a
little grease
to
the seal.
Install it using
a suitable
driver so that
the
face
of
the seal is
level
with the
su
rface
of
the housing.
2.
After
inserting
a
new pin,
punch
the housing
hole
to
secure the
pin in
place.
3. Regrease the
speedometer
gear.
4.
Install
the
speedometer
gear housing
so that
it
fits
in
the
speedometer
gear
drive
no
tches.
When
pro-
perly fi tted,
the
clearance between the
speedometer
gear
housing
and
the
gear drive
holding plate is
a
little less
th an
3
mm.
A.
Notches
Front Hub Disassembly
(including disc
removal):
Pull
the
speedqmeter
gear
housing
®
and
collar
ru;
off
the
front
hub.
•Remove
the screws
(f~
(2), and
take
the cap
:?~
off
the
right
side of
the
hub.
•Remove
the bolts
'iJ
(4),
and
take the
speedometer
gear
drive holding
plate
@
,
speedometer
gear
drive
~
s
:
,
and
disc
ti.
Using a
hook,
pull out
the
grease
seal
'H
'
and
remove
the
circlip
'j)
.
A.
Grease Seal
Insert
a
metal
rod
in to the hub
from the
right
side,
and
remove
the bearing
'B
on the left side
by
tapping
evenly
around
the
bearing
inner
race.
The
distance
collar
1
J
will come out
with
the
bearing.
Insert
a
metal
rod
into
the
hub from
the
left
side,
and
remove
the
other bearing
' .
iz
by
tappi ng
evenly around
th
e
bearing
inner
race.
Bearing
Removal
1.
Metal
Rod
3. Distance Collar
2.
Hub
4.
Ball
Bearing
Front Hub Assembly:
•Lu
bricate the new
ball
bearings (Pg.
143).
Before
installing the
wheel
bearings,
blow any
di rt
or foreign particles
out
of
the hub with compressed
air.
Install
the right
side
bal
l
bearing
using
the
wh
eel
bearing driver and the
bearing
driver
holder
(special
tools).
Press
Lhe
bearing until it
stops
at the bottom
of
the
hole.
NOTE:
The
wheel bearing
must be
installed with
the
shielded
side
facin
g
outward
.

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   Also See for Kawasaki Z250 1981

This manual is also suitable for:

Kz350 1981

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