Kawasaki KH250 (1972-1976) [12/129] Engine removal

Содержание

• Kawasaki 1
• Kh s series 1
• S series shop manual 1
• Shop mahuàl 1
• Foreward 3
• Foreword 3
• European model 4
• Model application 4
• Veer model begin frame no i major changes 4
• Table of contents 5
• General 6
• I specifications 6
• Specifications 6
• Kh250 a5 8
• Performance curves 8
• Construction 11
• Engine general maintenance 11
• Ii engine general maintenance 11
• Minor disassembly 11
• Engine removal 12
• Engine adjustments 14
• Engine mounting 14
• Idling adjustment 14
• Starter lever adjustment 16
• Clutch adjustment 17
• Oil pump adjustment 17
• Shift linkage adjustment 18
• Shift pedal linkage adjustment 18
• Air cleaner 19
• Engine detailed maintenance 19
• Iii engine detailed maintenance 19
• Cylinder cylinder head 20
• Piston piston pin 23
• Piston rings 26
• Engine left side 27
• Disassembly c d ignition 28
• System model 28
• Right cover 30
• Clutch clutch release 31
• Overhaul 31
• Primary gear 35
• External gear shift mech 36
• Operation 37
• Crankcase 39
• Crankshaft 41
• Transmission 43
• Operation 44
• Kick starter 47
• Lubrication system 49
• Oil pump 49
• Inspection and adjustment 51
• Carburetors 52
• Construction 58
• Jv frame 58
• Swing arm 59
• Wheels 61
• Inspection 65
• Assembly 66
• Hubs brakes sprocket 66
• J construction 66
• Table 28 rim runout 66
• Table 29 front hub 66
• A bearing and oil seal arc pressed into the 68
• And the coupling on the left side the rear brake drum which is of the same construction as the front drum fits against the coupling separated by rubber shock dampers that buffer torque changes 68
• B rear hub 68
• Brake mechanism brake panel brake shoes the sprocket which receives engine power and turns the rear wheel and the coupling the brake panel is mounted on the right side of the brake drum 68
• Coupling and the sprocket is bolted against it 68
• Rear brake drum assembly 68
• Rear hub mechanism 68
• Table 30 rear hub 68
• The rear hub consists of the brake drum rear 68
• Disassembly 69
• Brake lining measurement 70
• Overhaul 70
• Service limit 70
• Second cam play 73
• Assembly notes 74
• Disassembly 74
• Front wheel 74
• Front wheel and brake 74
• Front wheel on disc brake 74
• Installation notes 74
• Models disc brake brake lining wear indicator 74
• Removal 74
• Axje don t hold the axle instead otherwise tire speedometer gear drive will be damaged 75
• C front brake lever adjustment 75
• Die adjusting bolt a fraction of a turn so that the lever has less uian 75
• During use and if it needs additional adjustment parts are probably excessively worn or defective 75
• Hay in the brake lever can be adjusted oqt to 75
• Hold the gear box stationary and screw in the 75
• Inch 5 mm play and tighten the lock nut 2 align the parts as illustrated 75
• Keep the lever from vibrating but a small amount of play must be left in to ensure a full braking stroke 75
• The front brake itself is adjusted automatically 75
• To adjust lever play loosen die lock nut turn 75
• A disc brake disassembly 76
• B brake pads see caution removal remove the front wheel pg 72 76
• Brake fluid will damage painted surfaces any 76
• Brake parts mountings are as follows 76
• Caution 1 use only disc brake fluid isopropyl alcohol or 76
• Disc brake 76
• Do not use gasoline motor oil or any other 76
• Ethyl alcohol for cleaning brake parts but do not allow rubber parts to remain in contact with these fluids for a long period of time 76
• If any of the brake line fittings or the bleeder 76
• Mineral oils near disc brake parts these oils cause deterioration of rubber brake parts if oil spills on any brake parts it is very difficult to wash off and will eventually reach and break down the rubber 76
• Prescribed torque values for tightening disc 76
• Spilled fluid should be wiped off immediately 76
• Table 36 disc brake torque 76
• Valve is loosened at any time the al r must be bled from the brake pg 80 76
• Assembly notes 77
• Assembly note 78
• Installation note 78
• Removal 78
• Master cylinder 79
• Caliper assembly 80
• Bleeding the brake 81
• Brake fluid 81
• Braking release stroke 81
• Braking stroke 81
• Changing the brake fluid 81
• Warning 82
• Caliper parts wear 83
• Master cylinder parts wear 83
• Brake lining wear indicator 84
• Brake une damage 84
• Disassembly 84
• Disc wear warp 84
• From 74 models 84
• Handlebars 84
• Handlebars 1 construction 84
• Handlebar assembly 85
• Inspection 86
• Adjustment 87
• Assembly 87
• Construction operation 87
• Front fork drum brake models 87
• Front fork on drum brake 87
• Front shock absorber 87
• Models steering stem 87
• Disassembly 89
• Inspection 91
• Steering stem 91
• Assembly 92
• Bearing balls 92
• Disassembly 94
• Front fork 94
• Front fork disc brake models 94
• Front fork maintenance 94
• Front fork on disc brake models 94
• Front spring force 94
• Assembly notes 96
• Compression stroke 96
• Extension stroke 96
• Spring tension 96
• Fork oil 97
• Inner tube damage 97
• Tabic 45 fork spring free length 97
• Tabic 46 fork oil 97
• Disassembly 98
• Inspection 98
• Operation 98
• Rear shock absorbers 98
• Rear shock absorbers 1 construction 98
• Adjustment 99
• Rear shock absorber 99
• Construction operation 100
• Drive chain 100
• Inspection adjustment 100
• No of links type 100
• Table 47 chain specifications 100
• Construction 101
• Disassembly assembly 101
• Fuel oil tanks 101
• Disassembly 102
• Assembly 103
• Stands foot rests 103
• Assembly 104
• Construction 104
• Inspection 104
• Mufflers exhaust pipes 104
• Mufflers exhaust pipes 1 construction 104
• Removal 104
• Assembly 106
• Inspection 106
• Removal 106
• Ac generator rectifier 107
• Armature winding connection 107
• Electrical contact breaker models 107
• I ac generator rectifier 1 construction and operation 107
• V electrical 107
• Inspection 108
• 2 zener diode 109
• General 109
• Operation 109
• Thyristor 109
• Voltage regulator 109
• Inspection 110
• Caution 111
• Construction 111
• Ignition system 111
• Inspection 111
• Operation 111
• Ignition timing adjustment 112
• Ac generator 113
• Construction and operation 113
• Electrical 113
• Electrical cdi models 113
• Inspection 113
• Construction and operation 114
• Inspection 114
• Rectifier 114
• Caution 115
• Construction and operation 115
• Regulator 115
• Thyristor 115
• Zener diode 115
• Inspection 116
• Capacitor discharge ignition 117
• Ignition timing detection 117
• C d i unit 118
• Capacitor charge circuit 118
• Inspection 119
• Engine 120
• Jllbluc cdiuurclul 120
• Starting difficulty or failure to start 120
• Troubleshooting 120
• Vii troubleshooting 120
• Engine misfires rotation unstable 121
• Engine starts but stops right away 121
• Low output power 122
• Abnormal engine 123
• Gear shift trouble 123
• Sounds 123
• A w w a w xz a w w 124
• Absorbing bad 124
• Clutch ________ 124
• Control w 124
• Malfunction 124
• Poor steering 124
• Shock _______ 124
• U xz i v u 124
• ______ cknc _____________ 124
• Periodic maintenance chart 125
• Periodic maintenance guide 125
• Torque specifications 126
• Torque table 126
• S x xs xx x xx 127
• Toque for the bolts 127

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10 Right engine cover Oil pumo cover NOTE Before removing right engine cover first drain transmission oil Oil pump 6 Clutch and Primary Gear Spring plate friction plates clutch plates spring plate pusher Oil pump pinion Tachometer cable Primary gear Clutch hub Clutch housing 7 Pistons Exhaust pipes Cylinder heads Cylinders Air inlet pipes Piston pins pistons small end needle bearings Piston rings 3 ENGINE REMOVAL To remove the engine from the frame for replacement or disassembly the order given shows the minimum amount of parts that it is necessary to remove Any other order than that given here will involve more work and a greater number of parts to be removed Exhaust pipes Carburetors NOTE First close the fuel tap and remove the fuel pipe