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5.
Check shift cam dowel pins and side plate for
looseness, damage or wear. Replace as required.
6.
Check the shift cam stopper plate and circlip
and stopper for wear. Replace as required.
7.
Check the transmission shafts using acentering
device and dial gauge. I f any shaft is bent be-
yond specified limit, replace shaft.
Maximum run-out:
.03mm (.001")
8.
Carefully inspect each gear. Look for signs of
obvious heat damage (blue discoloration).
Check the gear teeth for signs of pitting,
galling or other extreme wear. Replace as
required.
9.
Check to see that each gear moves freely on
i t s shaft.
10. Check to see that all washers and clips are
properly installed and undamaged. Replace
bent or loose clips and bent washers.
11. Check to see that each gear properly engages
i t s counterpart on the shaft. Check the mating
dogs for rounded edges, cracks, or missing
portions. Replace as required.
N. Starter Drives
1. Electric Starter Clutch And Gears
a. Check pin contact surface of idle gear (2) for
pitting or other damage. I f severe, replacegear.
b. Check spring caps and springs for deformation
or damage. I f severe, replace as necessary.
c. Check starter clutch bolt (allen screw) for
looseness. I f loose, remove bolt and replace
with new bolt. Apply Loctite t o threads and
tighten to specified torque. Stake over end of
bolts in oil pump driven gear (1).
Starter clutch bolt torque:
2.8~3.2 m-kg
2. Kick Starter
a. Kick Gears
1) Check the kick gears for wear or scratches
on teeth, particularly in the chamfered area
of each gear.
(20~23
ft-lbs)
b. Kick Clip Spring
1) The kick clip is fitted to kick gear (5) and
slides i n the groove. A too-tight or loose-
fitting clip may result in improper operation.
I f too loose, bend the kick clip so that
the friction increases, or replace clip.
O. Crankcases and Strainer Cover
1. Check crankcases for cracks or other damage.
2. Clean all oil passages and blow out with com-
pressed air.
3. Strainer cover: Apply Loctite to strainer cover
bolts during reassembly.
P. Bearings and Oil Seals
1. After cleaning and lubricating bearings, rotate
inner race with a finger. I f rough spots are felt,
replace the bearing.
NOTE: Bearings are most easily removed or
installed if the housings are first heated to
approximately
Bring the case up t o proper temperature
slowly. Use an oven t o avoid distortion.
Check oil seal lips for damage and wear.
2.
Replace as required.
Q. Middle Gear Case
NOTE: This section involves external inspection
only. For middle gear case overhaul and adjust-
ment, refer to the Shaft Drive Section page 102.
1. Inspect entire exterior for leakage. If leakage
is found, the unit should be disassembled.
2. Check middle gear lash as follows:
a.
Support gear case in a vise by the output
shaft flange. Connect the lash measurement
tool
to the input shaft as shown.
95°~
125°C (200°~250°F).
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