Table of Contents
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ELECTRIC STARTER ...................................................................................5-45
CHECKING THE STARTER MOTOR .....................................................5-47
ASSEMBLING THE STARTER MOTOR................................................. 5-48
INSTALLING THE STARTER MOTOR ...................................................5-48
CLUTCH ........................................................................................................5-49
REMOVING THE CLUTCH ..................................................................... 5-52
CHECKING THE FRICTION PLATES.....................................................5-52
CHECKING THE CLUTCH PLATES .......................................................5-53
CHECKING THE CLUTCH SPRINGS.....................................................5-53
CHECKING THE CLUTCH HOUSING ....................................................5-53
CHECKING THE CLUTCH BOSS........................................................... 5-54
CHECKING THE PRESSURE PLATE ....................................................5-54
CHECKING THE PRIMARY DRIVE GEAR............................................. 5-54
CHECKING THE PRIMARY DRIVEN GEAR ..........................................5-54
CHECKING THE PULL LEVER SHAFT AND PULL ROD ......................5-54
INSTALLING THE CLUTCH.................................................................... 5-54
SHIFT SHAFT................................................................................................5-57
CHECKING THE SHIFT SHAFT ............................................................. 5-60
CHECKING THE STOPPER LEVER ......................................................5-60
INSTALLING THE SHIFT SHAFT ........................................................... 5-60
INSTALLING THE SHIFT ROD ...............................................................5-60
OIL PUMP...................................................................................................... 5-62
CHECKING THE OIL PUMP IDLE GEAR ............................................... 5-64
CHECKING THE OIL PUMP ................................................................... 5-64
CHECKING THE RELIEF VALVE ........................................................... 5-64
ASSEMBLING THE OIL PUMP...............................................................5-64
INSTALLING THE OIL PUMP .................................................................5-65
OIL PAN ........................................................................................................5-66
CHECKING THE OIL STRAINER ........................................................... 5-67
INSTALLING THE OIL PAN .................................................................... 5-67
CRANKCASE ................................................................................................5-68
DISASSEMBLING THE CRANKCASE....................................................5-71
CHECKING THE BALANCER DRIVE GEAR..........................................5-72
CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE (INTAKE
SIDE) ...................................................................................................... 5-72
CHECKING THE CRANKCASE ..............................................................5-72
CHECKING THE OIL NOZZLES ............................................................. 5-72
ASSEMBLING THE CRANKCASE.......................................................... 5-72
INSTALLING THE OIL PRESSURE SWITCH AND GEAR POSITION
SWITCH .................................................................................................5-75
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Table of Contents
Troubleshooting
