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Kawasaki KZ1300-A1 Quick Reference Manual Page 101

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DISASSEMBLY -- ENGINE REMOVED
1. The knock pins (2), timing chain guide, and rubber
plug must be in place.
A. Knock Pin
B. Timing Chain Guide and Rubber Plug
C. Timing Chain
D. Camshaft Chain
2.
The
output shaft
bearing cap must be installed in
the
upper
crankcase
half lightly with two bolts.
3.
The timing
chain and
camshaft chain must be engaged
with
each sprocket.
4.
The primary chain must be engaged with the crank-
shaft and the secondary shaft synchronized (Pg. 109).
5.
Check that
the
set rings for bearing outer races (3)
don't
stick
out
from
the upper crankcase
half.
6. Outer race
of
drive shaft needle bearing must be fit
with a set pin correctly and must be contact with the
upper
crankcase
half journal.
7. Check that there are no clearance between the sec-
ondary
chain
driven sprocket and the
collar,
and be-
tween
the
drive
chain
ball bearing inner race and the
collar.
eApply liquid
gasket to
the area of the mating surface
of the lower
crankcase
half, as shown below.
I
WARNING
I
~f I.iquid gasket a~here~ to any areas not
.
_
mdlcated,
the engme Oil passages may be
obstructed, causing engine seizure and possible accident
and injury.
Liquid Gasket Applied Area
eFit the lower crankcase half on the upper one, putting
the fingers of each shift fork into the grooves of the
gears.
~ =a~a~~rlin~:!;h::n~etge~f P~~:h~t:~
tween crankcase halves.
ePut each ofthe bolts (37) into the lower crankcase half
(See Fig. F17), and finger-tighten them.
eFoliow the tightening sequence numbers on the lower
cran kcase half: tighten the 8 mm bolts (18) first to
about 1.5 kg-m (11 ft-Ibs) and finally to 2.5 kg-m (18.0
ft-Ibs) of torque.
eTighten the 6 mm bolts (19) to 1.0 kg-m (87 in-Ibs)
of torque.
eCheck to see that
the
drive shaft, driven shaft, and
output shaft turn freely
.
Spinning the driven shaft,
shift
the
transmission through all gears to make certain
there is no binding and that all gears shift properly.
eApply a non-permanent locking agent to the threads
of output shaft bearing cap bolts (4), and tighten them
to 1.2 kg-m (104 in-Ibs) of torque.
A.
Apply a non-permanent locking agent to the threads.
-Clean the screen and push it in the screen body.
elnstall the screen body with screws
(3).
-Check that nozzles (2)
are
in place on the mating
sur-
face of low crankcase half and oil pan (See Figs. E167
and E168), and then install the oil
pan.
elnstall the oil pump
(Pg.
84).
eTurn the engine
upright.
ePut each of the 6 mm bolts (10) into the upper crank-
case half as shown
in
Fig.
F17, and tighten them to 1.0
kg-m (87 in-Ibs) of torque.
NOTE: Do not forget
to
install the pick-up coil lead
guide with the front right 6 mm bolt with 85 mm length.
elnstall
the
starter motor (Pg. 81).
elnstall the alternator cover (Pg. 85), clutch cover, left
engine
cover, and external shift mechanism cover (Pg.
82).
elnstall the engine (Pg. 98)
.
TRANSMISSION
Removal:
NOTE: When the drive shaft is to be disassembled,
remove the clutch while the engine is in the frame (Pg.
87).
When the driven shaft is to be disassembled,
101

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