Kawasaki J300 - Service manual > Drive Pulley
Drive Pulley Removal
- Remove the left crankcase cover (see Left Crankcase Cover Removal).
- Hold the drive pulley using the flywheel & pulley holder [A], and remove
the drive face nut [B] and washer.
Special Tool - Flywheel & Pulley Holder: 57001-1605
- Remove the drive pulley face [C].
- Remove:
Drive Pulley Collar [A]
Movable Drive Face [B]
- Remove the washer [A]
Drive Pulley Installation
- Clean the drive pulley faces and remove any grease from them.
- Install:
Washer
Movable Drive Face [A]
Drive Pulley Collar [B] - Set the drive belt [C] on the drive pulley collar.
- Install the drive pulley face.
- Install the washer so that the chamfer side [A] faces to the crankcase side.
- Hold the drive pulley using the flywheel & pulley holder [A], and
tighten the drive face nut [B].
Special Tool - Flywheel & Pulley Holder: 57001-1605
Torque - Drive Face Nut: 93 N*m (9.5 kgf*m, 69 ft*lb)
NOTE
- Be sure to clean the drive face off any grease.
- Install the removed parts (see appropriate chapters).
Drive Pulley Disassembly
- Remove the ramp plate [A].
- Remove the weight roller [A].
Drive Pulley Assembly
- Install the weight rollers to the drive pulley so that the collar side [A] of the weight rollers are faced to clockwise side [B].
- Install the weight rollers and the ramp plate into the movable drive face.
Drive Pulley Inspection
- Check each weight roller for damage.
If there is any damaged part, replace it.
- Measure each weight roller outside diameter [A].
If the weight roller is worn over the service limit, replace it.
Weight Roller Outside Diameter
Standard: 19.92 - 20.08 mm (0.7843 - 0.7905 in.)
Service Limit: 19.4 mm (0.764 in.)
- Check the drive pulley collar for damage.
If there is any damaged part, replace it.
- Measure the outside diameter [A] of the drive pulley collar sliding
surface.
If the collar is worn over the service limit, replace it.
Drive Pulley Collar Outside Diameter
Standard: 26.985 - 26.995 mm (1.0624 - 1.0628 in.)
Service Limit: 26.97 mm (1.062 in.)
- Measure the movable drive face bushing inside diameter [A].
If the bushing is worn over the service limit, replace it.
Movable Drive Face Bushing Inside Diameter
Standard: 27.01 - 27.04 mm (1.063 - 1.065 in.)
Service Limit: 27.07 mm (1.091 in.)
See also:
Kawasaki J300 - Service manual > Left Crankcase Cover
Left Crankcase Cover Removal Remove: Left Lower Fairing (see Lower Fairing Removal in the Frame chapter) Left Crankcase Outer Cover Bolts [A] Left Crankcase Outer Cover [B] Remove: Left Crankcase Cover Bolts [A] Left Crankcase Cover [B] and Gasket
Kawasaki J300 - Service manual > Clutch/Driven Pulley
Clutch/Driven Pulley Removal Remove the drive pulley (see Drive Pulley Removal). Hold the clutch outer [A] with the flywheel & pulley holder [B], and remove the clutch outer nut [C].
