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Kawasaki KZ1300-A1 Quick Reference Manual Page 36

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DISASSEMBLY --INTRODUCTION
INTRODUCTION TO DISASSEMBLY
Detail has not been spared in this section in order that the motorcycle can not only be taken apart
but also put back together properly as well.
Photographs, diagrams,
notes,
cautions,
warnings,
and
detailed descriptions have been included wherever necessary. Nevertheless, even a detailed account
has
limitations;
a certain amount of basic knowledoe is also reauired for successful work.
Especially note the following:
(1) Edges
Watch for sharp edges, especially during major engine disassembly and assembly. Protect your
hands with gloves or a piece of thick cloth when lifting the engine or turning it over.
(2) Dirt
Before removal and disassembly, clean the
motorcycle.
Any dirt entering the engine, carburetor
or other parts will work as an abrasive and shorten the life of the
motorcycle.
For the same
reason
,
before installing a new part, clean off any dust or metal fillings.
(3) Tightening Sequence
Where there is a tightening sequence indication in this Service Manual; the
bolts,
nuts, or screws
must be tightened in the order and method indicated. When installing a part with several bolts,
nuts, or screws; they shou Id all be started in their holes and tightened to a snug fit. Then tighten
them evenly, according to the tightening
sequence,
to the specified
torque.
This is to avoid
distortion of the part
and/
or causing gas or oil leakage. Conversely when loosening the
bolts,
nuts,
or screws
;
loosen all of them about a quarter of turn and then remove them.
(4) Torque
The torque values given in this Service Manual should always be adhered to. Either too little or
too much torque may lead to serious
damage.
Use a good quality, reliable torque wrench.
(5) Force
Common sense should dictate how much force is necessary in assembly and disassembly. If a
part seems especially difficult to remove or install, stop and examine what may be causing
the problem
.
Whenever tapping is necessary, tap lightly using a wooden or plastic-faced
mallet.
Use an impact driver for screws (particu larly for the removal of screws held by a locking agent)
in order to avoid damaging the screw
heads.
(6) Lubricant
Don't use just any oil or
grease.
Some oils and greases in particular should be used only in certa in
applications and may be harmful if used in an application for which they are not intended.
(7) Battery Ground
Before performing any disassembly operations on the motorcycle, remove the ground (-) lead
from the battery to prevent the possibility of accidentally turning the engine over while partially
disassembled.
(8) Engine Rotation
When turning the crankshaft by
hand,
always turn it in the direction of normal rotation
;
which is
counterclockwise, viewed from the right side of the
engine.
This will ensure proper
adjustments.
(9) Lubrication
Engine wear is generally at its maximum while the engine is warming up and before all the rubbing
surfaces have an adequate lubricative film.
During assembly, oil or grease (whichever is more
suitable) should be applied to any rubbing surface which has lost its lubricative film. Old grease
and dirty oil should be cleaned off. Deteriorated grease has lost its lubricative quality and may
contain abrasive foreign
particles.
(10) Press
A part installed using a press or
driver,
such as a wheel bearing, should first be coated with oil
on its outer or inner circumference so that it will go into place smoothly
.
(11) Oil Seal, Grease Seal
Replace any o il or grease seals that were removed with new
ones,
as removal generally damages
seals.
A seal guide is required for certain oil or grease seals during installation to avoid damage
to the seal lips. Before a shaft passes through a seal, apply a little oil, preferably high temperature
grease on the lips to reduce rubber to metal friction.
(12) Gasket,O Ring
When in doubt as to the condition of a gasket or
0
ring, replace it with a new one. The mating
surfaces around the gasket should be free of foreign matter and perfectly smooth to avoid oil
or compression leaks.
36

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