Question re: removing tachometer pinion (camshaft)

Hiya folks ... I'm trying to install a camshaft, and part of that process is removing the tachometer pinion before the camshaft goes in...

The factory manual states that "CAUTION: Attempting to install the camshaft with the tachometer pinion left in the cylinder head may cause tachometer gear damage."

I've unscrewed the tachometer cable, and it's come free from the pinion... and I can see the pinion still inside the head, but I can't figure out how to get it out?! I've tried needle-nose pliers, pulling straight out AND trying to "unscrew" it out... neither seem to budge it. It will spin freely, and I can see it clearly if I look through where the camshaft was.

This is my first time tearing a motor apart, so I'm being gentle with it.. do I just need to be more 'manly' with it? Is there some trick to getting this thing out?

Thanks for any advice!

Bike is an '82 KZ250, btw.

If needed, a service manual should be available through one or both of these links:

www.kzrider.com/forum/13-bike-related/47...test-download#472613

merzymania.blogspot.com/2008/09/manual-b...nload-files-for.html

Might also find a helpful parts diagram on kawasaki.com, which includes parts diagrams, part names, part numbers, models sharing same part, availability, etc.
Here's a link for help with navigating the site and finding information.
kzrider.com/index.php?option=com_kunena&...w&catid=13&id=376734

Good Fortune!

You never need to remove the pinion. Don't care what the manual says. It's a complete waste of time and effort. Well on second thought I just saw it's a KZ250, so disregard. I was thinking of the larger KZ 4 cyl.

RonKZ650 wrote: You never need to remove the pinion. Don't care what the manual says. It's a complete waste of time and effort. Well on second thought I just saw it's a KZ250, so disregard. I was thinking of the larger KZ 4 cyl.

Sooooo, I *do* need to remove it?

Anyone?

Well, apparently, I didn't need to remove it - everything is back to normal after reassembly (as far as this piece is concerned, anyway).

On my 1000 i just wiggled the gear back and forth to get it to mate up with the camshaft while installing cams. worked great for me.

Hey any advice for someone who does need to remove the pinion? I'm transferring one from one cylinder head to another and I wiggled the bolt head thing free and now it just spins freely.

Any help or direction will be appreciated!

I figured it out. You just need to pull it out

cmuns,
Nobody has posted to this thread since May 2012, and many of the posters are no longer around. In the future, you might get better responses by starting a new thread.