Kawasaki KLE500 (2004) [340/401] 26 electrical system

Kawasaki KLE500 (2004) [340/401] 26 electrical system
16-26 ELECTRICAL SYSTEM
Charging System
Alternator Rotor/Starter Clutch Installation
Apply a non-permanent locking agent to the threads of the
starter clutch Allen bolts, and tighten them to the specified
torque in assembling the starter clutch onto the alternator
rotor.
Torque - Starter Clutch Allen Bolts: 34 N·m (3.5 kgf·m, 25
ft·lb)
Be careful that the rollers do not drop out of the starter
clutch during assembly.
Using a high flash-point solvent, clean off any oil or dirt
that may be on the crankshaft taper [A] and rotor tapered
hole [B].
Fit the woodruff key securely in the slot [C] in the crank-
shaft before installing the rotor assembly on the crank-
shaft.
Tighten the rotor bolt while holding the rotor steady with
the flywheel holder, and turn the rotor bolt counterclock-
wise to install it.
Torque - Alternator Rotor Bolt: 69 N·m (7.0 kgf·m, 51 ft·lb)
Special Tool - Flywheel Holder: 57001-1410
Apply silicone sealant to the area [A] where the mating
surface ends of the crankcase touch the alternator cover
gasket.
Sealant - Kawasaki Bond (Sili co n e Sealant): 5 60 1 9-1 20
Apply silicone sealant around the circumference of the
wiring grommets before setting it in the notch in the al-
ternator cover.
Sealant - Kawasaki Bond (Liquid Gasket): 92104-1063
Check that knock pins [B] are in place on the crankcase.
Tighten the alternator cover bolts.
Torque - Alternator Cover Bolts: 11 N·m (1.1 kgf·m, 95 in·lb)
Install the other removed parts.
Check the engine oil level, and add if necessary (see En-
gine Oil Level Inspection in the Engine Lubrication Sys-
tem chapter).
Alternator Stator Removal
NOTE
To keep the loss of engine oil to a minimum, set the
motorcycle vertically.
Remove the alternator cover (see Alternator Rotor and
Starter Clutch Removal).

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