![Kawasaki WORKHORSE 250 (2003) [139/322] Engine removal installation 8 5](/img/pdf.png)
Kawasaki WORKHORSE 250 (2003) [139/322] Engine removal installation 8 5
![Kawasaki WORKHORSE 250 (2003) [139/322] Engine removal installation 8 5](/views2/1121215/page139/bg8b.png)
ENGINE REMOVAL/INSTALLATION 8-5
Engine Removal/Installation
Engine Installation
•
Be sure the damper [A] is in place.
•
Apply grease the splines at the driven gear shaft [A] and
front end of the propeller shaft [B].
•
Support the vehicle so that the rear wheels are off the
ground.
•
Fit the driven gear shaft to the propeller shaft while rotat-
ing one rear wheel slowly.
•
Tighten:
Torque - Engine Bracket Bolts and Nuts: 26 N·m (2.7 kgf·m,
20 ft·lb)
Engine Mounting Nut (M8): 29 N·m (3.0 kgf·m, 22
ft·lb)
Engine Mounting Nuts (M10): 39 N·m (4.0 kgf·m,
29 ft·lb)
•
Route the hoses, cables, and leads properly (see Appen-
dix c hapter).
•
Adjust:
Reverse Cable (see Crankshaft/Transmission chapter)
Throttle Lever Free Play (see Periodic Maintenance
chapter)
Engine Oil (see Engine Lubrication System chapter)
Idle Speed (see Fuel System chapter)
Содержание
- Tables 1
- Quick reference guide 3
- All terrain vehicle service manual 5
- Klf 250 bayou 250 workhorse 250 5
- List of abbreviations 6
- Read owner s manual before operating 6
- Emission control information 7
- The phrase remove or render inoperative any device or element of design has been generally interpreted as follows 1 tampering does not include the temporary removal or rendering inoperative of de vices or elements of design in order to perform maintenance 2 tampering could include a maladjustment of vehicle components such that the emission standards are ex ceeded b use of replacement parts or accessories which adversely affect the performance or durability of the motorcycle c addition of components or accessories that result in the vehicle exceeding the stan dards d permanently removing disconnecting or rendering inoperative any component or element of design of the emission control systems 7
- Please do not tamper with noise control system us model only 8
- Foreword 9
- How to use this manual 9
- General information 11
- General information 1 1 11
- Table of contents 11
- 2 general information 12
- Before servicing 12
- Before starting to perform an inspection service or carry out a 12
- Especially note the following 12
- Before servicing 13
- General information 1 3 13
- 4 general information 14
- Before servicing 14
- Two color electrical wire 14
- General information 1 5 15
- Model identification 15
- 6 general information 16
- General specifications 16
- General information 1 7 17
- General specifications 17
- 8 general information 18
- General specifications 18
- General information 1 9 19
- Prefixes for units 19
- Unit conversion table 19
- Units of force 19
- Units of length 19
- Units of mass 19
- Units of power 19
- Units of pressure 19
- Units of speed 19
- Units of torque 19
- Units of volume 19
- Periodic maintenance 21
- Periodic maintenance 2 1 21
- Table of contents 21
- 2 periodic maintenance 22
- Periodic maintenance chart 22
- Basic torque for general fasteners 23
- Periodic maintenance 2 3 23
- Torque and locking agent 23
- 4 periodic maintenance 24
- Torque and locking agent 24
- Periodic maintenance 2 5 25
- Torque and locking agent 25
- 6 periodic maintenance 26
- Specifications 26
- Fuel system 27
- Periodic maintenance 2 7 27
- Periodic maintenance procedures 27
- Throttle lever free play 27
- Throttle lever free play adjustment 27
- Throttle lever free play inspection 27
- 8 periodic maintenance 28
- Periodic maintenance procedures 28
- Warning 28
- Periodic maintenance 2 9 29
- Periodic maintenance procedures 29
- Warning 29
- 10 periodic maintenance 30
- Engine top end 30
- Periodic maintenance procedures 30
- Valve clearance when cold 30
- Warning 30
- Clutch adjustment 31
- Clutches 31
- Periodic maintenance 2 11 31
- Periodic maintenance procedures 31
- Warning 31
- 12 periodic maintenance 32
- Engine lubrication system 32
- Engine oil 32
- Periodic maintenance procedures 32
- Periodic maintenance 2 13 33
- Periodic maintenance procedures 33
- Standard tire 33
- Tire tread depth 33
- Wheels tires 33
- 14 periodic maintenance 34
- Final drive 34
- Final gear case oil 34
- Periodic maintenance procedures 34
- Brakes 35
- Front brake lever free play 35
- Periodic maintenance 2 15 35
- Periodic maintenance procedures 35
- 16 periodic maintenance 36
- Brake pedal free play 36
- Cam lever angle 36
- Periodic maintenance procedures 36
- Rear parking brake lever free play 36
- Warning 36
- Cam lever angle 37
- Periodic maintenance 2 17 37
- Periodic maintenance procedures 37
- Rear parking brake lever and pedal free play adjustment 37
- Warning 37
- 18 periodic maintenance 38
- Electrical system 38
- Periodic maintenance procedures 38
- Spark plug gap 38
- Steering 38
- Brake light switch timing 39
- General lubrication 39
- Periodic maintenance 2 19 39
- Periodic maintenance procedures 39
- 20 periodic maintenance 40
- Periodic maintenance procedures 40
- Bolts and nuts tightening 41
- Periodic maintenance 2 21 41
- Periodic maintenance procedures 41
- Tightness inspection 41
- Fuel system 43
- Fuel system 3 1 43
- Table of contents 43
- Exploded view 45
- Fuel system 3 3 45
- 4 fuel system 46
- Specifications 46
- Fuel system 3 5 47
- Special tools and sealant 47
- 6 fuel system 48
- Throttle case removal disassembly 48
- Throttle lever and cable 48
- Throttle lever free play adjustment 48
- Throttle lever free play inspection 48
- Fuel system 3 7 49
- Throttle lever and cable 49
- Warning 49
- 8 fuel system 50
- Throttle cable lubrication and inspection 50
- Throttle lever and cable 50
- Choke cable lubrication and inspection 51
- Choke lever and cable 51
- Choke lever and cable installation 51
- Choke lever lubrication 51
- Choke lever removal 51
- Fuel system 3 9 51
- Warning 51
- 10 fuel system 52
- Carburetor 52
- Carburetor pilot screw setting 52
- Idle speed 52
- Warning 52
- Carburetor 53
- Float height 53
- Fuel level 53
- Fuel system 3 11 53
- 12 fuel system 54
- Carburetor 54
- Carburetor removal 54
- Fuel system cleanliness inspection 54
- Warning 54
- Carburetor 55
- Carburetor disassembly 55
- Carburetor installation 55
- Fuel system 3 13 55
- Warning 55
- 14 fuel system 56
- Carburetor 56
- Carburetor assembly 56
- Caution 56
- Warning 56
- Carburetor 57
- Carburetor cleaning 57
- Carburetor inspection 57
- Caution 57
- Fuel system 3 15 57
- Warning 57
- 16 fuel system 58
- Carburetor 58
- Air cleaner 59
- Fuel system 3 17 59
- Warning 59
- 18 fuel system 60
- Air cleaner 60
- Air cleaner draining 60
- Air cleaner element cleaning and inspection 60
- Air cleaner housing removal 60
- Fuel system 3 19 61
- Fuel tank 61
- Fuel tank installation 61
- Fuel tank removal 61
- Warning 61
- 20 fuel system 62
- Fuel tank 62
- Fuel tank and fuel tap cleaning 62
- Fuel tap installation 62
- Fuel tap removal 62
- Warning 62
- Fuel level gauge removal 63
- Fuel system 3 21 63
- Fuel tank 63
- Fuel tap inspection 63
- Warning 63
- 22 fuel system 64
- Fuel level gauge check 64
- Fuel level gauge installation 64
- Fuel tank 64
- Warning 64
- Engine top end 65
- Engine top end 4 1 65
- Table of contents 65
- Engine top end 4 3 67
- Exploded view 67
- Engine top end 4 5 69
- Exploded view 69
- 6 engine top end 70
- Specifications 70
- Engine top end 4 7 71
- Specifications 71
- 8 engine top end 72
- Specifications 72
- Engine top end 4 9 73
- Special tools and sealant 73
- 10 engine top end 74
- Special tools and sealant 74
- Camshaft chain tensioner 75
- Engine top end 4 11 75
- 12 engine top end 76
- Camshaft sprocket 76
- Camshaft sprocket 77
- Engine top end 4 13 77
- 14 engine top end 78
- Rocker arms and shafts 78
- Engine top end 4 15 79
- Rocker arm and shaft installation 79
- Rocker arm and shaft removal 79
- Rocker arms and shafts 79
- 16 engine top end 80
- Rocker arm and shaft inspection 80
- Rocker arm inside diameter 80
- Rocker arms and shafts 80
- Rocker shaft diameter 80
- Cam height 81
- Camshaft 81
- Engine top end 4 17 81
- 18 engine top end 82
- Camshaft chain and guides 82
- Camshaft chain guide installation 82
- Camshaft chain guide removal 82
- Camshaft chain guide wear 82
- Camshaft chain installation 82
- Camshaft chain removal 82
- Caution 82
- Cylinder compression usable range 83
- Cylinder head 83
- Engine top end 4 19 83
- 20 engine top end 84
- Compression too high 84
- Cylinder head 84
- Cylinder head removal 84
- Wet compression increase 84
- Wet compression no change 84
- Cylinder head 85
- Cylinder head bolt torque 85
- Engine top end 4 21 85
- 22 engine top end 86
- Cylinder head 86
- Cylinder head cleaning 86
- Cylinder head warp 86
- Engine top end 4 23 87
- Valve clearance adjustment 87
- Valve clearance inspection 87
- Valve removal 87
- Valves guides seats springs oil seals 87
- 24 engine top end 88
- Valves guides seats springs oil seals 88
- Engine top end 4 25 89
- Valve valve guide clearance wobble method 89
- Valves guides seats springs oil seals 89
- 26 engine top end 90
- Valve seat surface outside diameter 90
- Valve seat surface width 90
- Valves guides seats springs oil seals 90
- Engine top end 4 27 91
- Valves guides seats springs oil seals 91
- 28 engine top end 92
- Valves guides seats springs oil seals 92
- Engine top end 4 29 93
- Valves guides seats springs oil seals 93
- Cylinder and piston 95
- Engine top end 4 31 95
- 32 engine top end 96
- Cylinder and piston 96
- Cylinder and piston 97
- Cylinder inside diameter 97
- Engine top end 4 33 97
- Piston diameter 97
- 34 engine top end 98
- Cylinder and piston 98
- Piston cylinder clearance 98
- Piston ring groove clearance 98
- Piston ring groove width 98
- Cylinder and piston 99
- Engine top end 4 35 99
- Piston ring end gap 99
- Piston ring thickness 99
- 36 engine top end 100
- Caution 100
- Exhaust pipe removal 100
- Exhaust system 100
- Muffler removal 100
- Spark arrester cleaning 100
- Engine top end 4 37 101
- Exhaust system 101
- Engine right side 103
- Engine right side 5 1 103
- Table of contents 103
- Engine right side 5 3 105
- Exploded view 105
- 4 engine right side 106
- Specifications 106
- Engine right side 5 5 107
- Special tools and sealant 107
- 6 engine right side 108
- Engine right side 108
- Engine right side disassembly 108
- Engine right side 109
- Engine right side 5 7 109
- 8 engine right side 110
- Engine right side 110
- Engine right side 111
- Engine right side 5 9 111
- 10 engine right side 112
- Clutches 112
- Primary clutch housing inside diameter 112
- Primary clutch shoe groove depth 112
- Clutches 113
- Engine right side 5 11 113
- Friction and steel plate warp 113
- Friction plate thickness 113
- Friction plate warp 113
- Friction plate wear 113
- One way clutch inspection 113
- Steel plate warp 113
- 12 engine right side 114
- Clutch spring free length 114
- Clutch spring free length measurement 114
- Clutches 114
- If any of the springs a is shorter than the service limit it must be replaced 114
- Crankshaft diameter a 115
- Engine right side 5 13 115
- Gear backlash 115
- Primary gear crankshaft wear 115
- Primary gear inside diameter a 115
- Primary reduction 115
- Secondary gear collar diameter b 115
- Secondary gear collar wear 115
- Secondary gear inside diameter a 115
- Recoil starter 117
- Recoil starter 6 1 117
- Table of contents 117
- Exploded view 119
- Recoil starter 6 3 119
- 4 recoil starter 120
- Recoil starter 120
- Warning 120
- Recoil starter 121
- Recoil starter 6 5 121
- Warning 121
- 6 recoil starter 122
- Recoil starter 122
- Recoil starter 123
- Recoil starter 6 7 123
- Warning 123
- Engine lubrication system 125
- Engine lubrication system 7 1 125
- Table of contents 125
- Engine lubrication system 7 3 127
- Exploded view 127
- 4 engine lubrication system 128
- Specifications 128
- Engine lubrication system 7 5 129
- Engine oil flow chart 129
- 6 engine lubrication system 130
- Engine oil and oil filter 130
- Warning 130
- Engine lubrication system 7 7 131
- Engine oil and oil filter 131
- Warning 131
- 8 engine lubrication system 132
- Oil pressure relief valve 132
- Warning 132
- Engine lubrication system 7 9 133
- Oil pump 133
- Oil pump installation 133
- Oil pump removal 133
- 10 engine lubrication system 134
- Oil pipe 134
- Oil pipe installation 134
- Oil pipe removal 134
- Engine removal installation 135
- Engine removal installation 8 1 135
- Table of contents 135
- Engine removal installation 8 3 137
- Exploded view 137
- 4 engine removal installation 138
- Engine removal 138
- Engine removal installation 138
- Engine installation 139
- Engine removal installation 139
- Engine removal installation 8 5 139
- Crankshaft transmission 141
- Crankshaft transmission 9 1 141
- Table of contents 141
- Crankshaft transmission 9 3 143
- Exploded view 143
- Crankshaft transmission 9 5 145
- Exploded view 145
- 6 crankshaft transmission 146
- Specifications 146
- Crankshaft transmission 9 7 147
- Special tools and sealant 147
- 8 crankshaft transmission 148
- Crankcase 148
- Crankcase 149
- Crankshaft transmission 9 9 149
- Warning 149
- 10 crankshaft transmission 150
- Crankcase 150
- Crankshaft balancer shaft and connection rod 151
- Crankshaft transmission 9 11 151
- 12 crankshaft transmission 152
- Connecting rod big end seizure 152
- Crankshaft balancer shaft and connection rod 152
- Connecting rod big end radial clearance 153
- Connecting rod big end side clearance 153
- Crankshaft balancer shaft and connection rod 153
- Crankshaft transmission 9 13 153
- 14 crankshaft transmission 154
- Crankshaft balancer shaft and connection rod 154
- Crankshaft runout 154
- Connecting rod bend 155
- Connecting rod twist 155
- Crankshaft balancer shaft and connection rod 155
- Crankshaft transmission 9 15 155
- 16 crankshaft transmission 156
- Transmission 156
- Crankshaft transmission 9 17 157
- External shift mechanism inspection 157
- Reverse knob free play 157
- Reverse knob free play adjustment 157
- Reverse shift mechanism removal 157
- Transmission 157
- 18 crankshaft transmission 158
- Transmission 158
- Crankshaft transmission 9 19 159
- Transmission 159
- 20 crankshaft transmission 160
- Gear shift fork groove width 160
- Shift drum assembly 160
- Shift drum groove width 160
- Shift drum inspection 160
- Shift fork bending 160
- Shift fork ear thickness 160
- Shift fork guide pin diameter 160
- Shift fork wear 160
- Transmission 160
- Transmission gear inspection 160
- Crankshaft transmission 9 21 161
- Transmission 161
- 22 crankshaft transmission 162
- Transmission 162
- Ball bearing needle bearing and oil seal 163
- Crankshaft transmission 9 23 163
- Table of contents 165
- Wheels tires 165
- Wheels tires 10 1 165
- Exploded view 167
- Wheels tires 10 3 167
- 4 wheels tires 168
- Specifications 168
- Special tool and sealant 169
- Wheels tires 10 5 169
- 6 wheels tires 170
- Wheel alignment 170
- Caution 171
- Toe in inspection 171
- Toe in of front wheels 171
- Wheel alignment 171
- Wheels tires 10 7 171
- 8 wheels tires 172
- Wheel alignment 172
- Wheels rims 173
- Wheels tires 10 9 173
- 10 wheels tires 174
- Wheels rims 174
- Warning 175
- Wheels tires 10 11 175
- 12 wheels tires 176
- Maximum tire air pressure to seat beads when cold 176
- Tire air pressure when cold 176
- Warning 176
- Rear hub 177
- Wheels tires 10 13 177
- Final drive 179
- Final drive 11 1 179
- Table of contents 179
- Exploded view 181
- Final drive 11 3 181
- Exploded view 183
- Final drive 11 5 183
- 6 final drive 184
- Specifications 184
- Final drive 11 7 185
- Special tools and sealant 185
- 8 final drive 186
- Output bevel gear case 186
- Final drive 11 9 187
- Output bevel gear case 187
- 10 final drive 188
- Output bevel gear case 188
- Final drive 11 11 189
- Output bevel gear adjustment 189
- Output bevel gear case 189
- Output drive gear installation 189
- Output drive gear removal 189
- 12 final drive 190
- Backlash related parts 190
- Output bevel gear case 190
- Drive gear shims 191
- Driven bevel gear shims 191
- Final drive 11 13 191
- Output bevel gear case 191
- 14 final drive 192
- Bevel gear backlash front 192
- Output bevel gear case 192
- Bevel gear inspection 193
- Final drive 11 15 193
- Output bevel gear case 193
- 16 final drive 194
- Ball bearing inspection 194
- Cam damper inspection 194
- Oil seal inspection 194
- Output bevel gear case 194
- Final drive 11 17 195
- Propeller shaft 195
- Propeller shaft removal 195
- 18 final drive 196
- Propeller shaft 196
- Final drive 11 19 197
- Propeller shaft 197
- Propeller shaft joint and pinion gear joint inspection 197
- Propeller shaft joint boot inspection 197
- 20 final drive 198
- Rear axle 198
- Final drive 11 21 199
- Rear axle 199
- 22 final drive 200
- Axle shaft pipe assembly 200
- Rear axle 200
- Final drive 11 23 201
- Final gear case 201
- 24 final drive 202
- Final gear case 202
- Final drive 11 25 203
- Final gear case 203
- 26 final drive 204
- Bevel gear backlash rear 204
- Final gear case 204
- Pinion gear shims 204
- Ring gear shims 204
- Final drive 11 27 205
- Final gear case 205
- Final drive 11 29 207
- Final gear case 207
- Pinion gear assembly 207
- Pinion gear disassembly 207
- 30 final drive 208
- Ball bearing inspection 208
- Bevel gear inspection 208
- Caution 208
- Final gear case 208
- Oil seal inspection 208
- Brakes 209
- Brakes 12 1 209
- Table of contents 209
- Brakes 12 3 211
- Exploded view 211
- 4 brakes 212
- Specifications 212
- Brake adjustment 213
- Brake pedal free play inspection 213
- Brake pedal position adjustment 213
- Brake pedal position inspection 213
- Brakes 12 5 213
- Cam lever angle adjustment front and rear 213
- Front brake adjustment 213
- Rear parking brake lever and brake pedal free play adjustment 213
- Rear parking brake lever free play inspection 213
- 6 brakes 214
- Brake adjustment 214
- Cam lever angle front and rear 214
- Warning 214
- Brake drum and panel 215
- Brakes 12 7 215
- Front brake panel removal disassembly 215
- Warning 215
- 8 brakes 216
- Brake drum and panel 216
- Warning 216
- Brake drum and panel 217
- Brakes 12 9 217
- 10 brakes 218
- Brake drum and panel 218
- Rear brake panel removal disassembly 218
- Warning 218
- Brake drum and panel 219
- Brakes 12 11 219
- 12 brakes 220
- Brake drum and panel 220
- Brake drum wear 221
- Brake maintenance 221
- Brake shoe lining thickness front and rear 221
- Brake shoe lining wear 221
- Brakes 12 13 221
- Caution 221
- Front brake drum inside diameter 221
- Rear brake drum inside diameter 221
- 14 brakes 222
- Brake cam and cam hole wear 222
- Brake cam diameter 222
- Brake maintenance 222
- Brake shoe spring inspection 222
- Cam hole inside diameter 222
- Brake maintenance 223
- Brakes 12 15 223
- 16 brakes 224
- Brake cable installation 224
- Brake cable lubrication 224
- Brake cable removal 224
- Brake pedal and cables 224
- Brake pedal installation 224
- Suspension 225
- Suspension 13 1 225
- Table of contents 225
- Exploded view 227
- Suspension 13 3 227
- 4 suspension 228
- Shock absorbers 228
- Front suspension arm installation 229
- Front suspension arm removal 229
- Rear suspension arm removal 229
- Suspension 13 5 229
- Suspension arms 229
- 6 suspension 230
- Suspension arms 230
- Front suspension arm lubrication 231
- Suspension 13 7 231
- Suspension arm inspection 231
- Suspension arms 231
- Steering 233
- Steering 14 1 233
- Table of contents 233
- Exploded view 235
- Steering 14 3 235
- 4 steering 236
- Specifications 236
- Caution 237
- Steering 237
- Steering 14 5 237
- Steering stem removal 237
- 6 steering 238
- Caution 238
- Steering 238
- Steering knuckle removal 238
- Steering stem installation 238
- Steering 239
- Steering 14 7 239
- 8 steering 240
- Steering 240
- Tie rod end installation 240
- Tie rod length 240
- Steering 14 9 241
- Steering maintenance 241
- 10 steering 242
- Steering maintenance 242
- Handlebar 243
- Steering 14 11 243
- Frame 15 1 245
- Table of contents 245
- Exploded view 249
- Frame 15 5 249
- 6 frame 250
- Seat installation 250
- Seat removal 250
- Frame 15 7 251
- Front and rear fenders 251
- Front fender removal 251
- 8 frame 252
- Front and rear fenders 252
- Front fender installation 252
- Frame 15 9 253
- Front and rear fenders 253
- Rear fender removal 253
- 10 frame 254
- Front and rear fenders 254
- Rear fender installation 254
- Frame 15 11 255
- Front guard removal 255
- Rear guard removal 255
- Electrical system 257
- Electrical system 16 1 257
- Table of contents 257
- Electrical system 16 3 259
- Exploded view 259
- Electrical system 16 5 261
- Exploded view 261
- 6 electrical system 262
- Specifications 262
- Electrical system 16 7 263
- Special tools and sealant 263
- 8 electrical system 264
- Parts location 264
- Electrical system 16 9 265
- Precautions 265
- Electrical system 16 11 267
- Electrical wiring 267
- 12 electrical system 268
- Battery 268
- Battery 269
- Electrical system 16 13 269
- Warning 269
- 14 electrical system 270
- Battery 270
- Caution 270
- Ordinary charging 270
- Warning 270
- Battery 271
- Battery charging rate time table 271
- Battery test charging 271
- Battery troubleshooting guide 271
- Electrical system 16 15 271
- 16 electrical system 272
- Battery 272
- Alternator cover installation 273
- Alternator cover removal 273
- Charging system 273
- Electrical system 16 17 273
- 18 electrical system 274
- Alternator rotor removal 274
- Caution 274
- Charging system 274
- Alternator rotor installation 275
- Charging system 275
- Electrical system 16 19 275
- 20 electrical system 276
- Alternator stator installation 276
- Alternator stator removal 276
- Charging system 276
- Charging system 277
- Electrical system 16 21 277
- Regulator rectifier output voltage 277
- 22 electrical system 278
- Alternator output voltage 278
- Charging system 278
- Stator coil resistance 278
- Charging system 279
- Electrical system 16 23 279
- Rectifier circuit inspection 279
- 24 electrical system 280
- Caution 280
- Charging system 280
- Charging system 281
- Charging system circuit 281
- Electrical system 16 25 281
- 26 electrical system 282
- Caution 282
- Ignition coil removal 282
- Ignition system 282
- Spark plug cleaning inspection 282
- Spark plug gap inspection 282
- Spark plug removal installation 282
- Warning 282
- Electrical system 16 27 283
- Ignition coil arcing distance 283
- Ignition system 283
- Warning 283
- 28 electrical system 284
- Ignition coil primary peak voltage 284
- Ignition coil winding resistance 284
- Ignition system 284
- Warning 284
- Crankshaft sensor resistance 285
- Electrical system 16 29 285
- Ignition system 285
- 30 electrical system 286
- Connections 286
- Crankshaft sensor peak voltage 286
- Ignition system 286
- Electrical system 16 31 287
- Ignition system 287
- Ignition timing 287
- 32 electrical system 288
- Ignition system 288
- 34 electrical system 290
- Caution 290
- Electric starter system 290
- Starter motor installation 290
- Starter motor removal 290
- Electric starter system 291
- Electrical system 16 35 291
- Starter motor assembly 291
- Starter motor disassembly 291
- 36 electrical system 292
- Commutator cleaning inspection 292
- Electric starter system 292
- Commutator diameter 293
- Electric starter system 293
- Electrical system 16 37 293
- Starter motor brush length 293
- 38 electrical system 294
- Brush plate and terminal bolt inspection 294
- Electric starter system 294
- Starter circuit relay inspection 294
- Starter relay inspection 294
- Testing relay 294
- Electric starter circuit 295
- Electric starter system 295
- Electrical system 16 39 295
- Testing relay 295
- 40 electrical system 296
- Electric starter system 296
- Electrical system 16 41 297
- Starter motor clutch 297
- 42 electrical system 298
- Starter chain and sprockets 298
- Torque limiter inspection 298
- Electrical system 16 43 299
- Lighting system 299
- 44 electrical system 300
- Lighting system 300
- Electrical system 16 45 301
- Lighting system 301
- Lighting system circuit 301
- 46 electrical system 302
- Switches 302
- A main fuse removal 303
- Caution 303
- Electrical system 16 47 303
- Fuse inspection 303
- Appendix 307
- Appendix 17 1 307
- Table of contents 307
- 2 appendix 308
- Cable wire and hose routing 308
- Appendix 17 3 309
- Cable wire and hose routing 309
- 4 appendix 310
- Cable wire and hose routing 310
- Appendix 17 5 311
- Cable wire and hose routing 311
- 6 appendix 312
- Cable wire and hose routing 312
- Appendix 17 7 313
- Cable wire and hose routing 313
- 8 appendix 314
- Cable wire and hose routing 314
- Appendix 17 9 315
- Cable wire and hose routing 315
- 10 appendix 316
- Cable wire and hose routing 316
- Appendix 17 11 317
- Cable wire and hose routing 317
- 12 appendix 318
- Troubleshooting guide 318
- Appendix 17 13 319
- Troubleshooting guide 319
- 14 appendix 320
- Troubleshooting guide 320
- Appendix 17 15 321
- Troubleshooting guide 321
- Model application 322
- Part no 9924 1284 03 322
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