157
FI580
INSPECTING STATOR COIL/
MAGNETO COVER ASSEMBLY
1. Inspect the stator coil for burned or discolored wiring,
broken or missing hold-down clips, or loose cap screws.
2. Inspect the bearings in the magneto housing for dis-
coloration, roughness when rotated, and secure fit in
bearing bores.
REPLACING STATOR COIL/
CRANKSHAFT POSITION SENSOR
1. Remove the three cap screws securing the stator coil,
two cap screws securing the crankshaft position sen-
sor, and two cap screws from the harness hold-down.
2. Lift the rubber grommet out of the housing; then
remove the stator coil/crankshaft position sensor.
Account for and note the position of the harness
hold-down under the crankshaft position sensor.
H2-017A
H2-027
3. Install the new stator coil assembly and secure with
three cap screws using a drop of red Loctite #271 on
each. Tighten according to the chart.
4. Place the stator wire harness hold-down into posi-
tion; then install the crankshaft position sensor and
secure with two cap screws. Tighten securely.
5. Install the upper cable hold-down and secure with
the cap screws. Tighten securely.
H2-017
Installing Left-Side
Components
1. Thoroughly clean all gasket material and sealant
from mating surfaces.
2. Install a new O-ring on the oil filler cover and coat it
with clean engine oil; then install the oil filler cover
into the crankcase and secure with the cap screws.
Tighten to 8 ft-lb.
GZ250
3. Clean the countershaft and trigger splines thoroughly
and install the inner snap ring onto the shaft; then
apply green Loctite #620 to the trigger and counter-
shaft splines and install the trigger. Secure with a flat
washer and outer snap ring.
Cover
Bolt Type
ft-lb
N-m
Original
Hex-Head
11
15
New
Hex-Head
13
18
