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11. Check to see that each gear properly
engages its counterpart on the shaft.
Check the mating dogs for rounded edges,
cracks, or missing portions. Replace as
required.
starter gears and clip spring
0. Electric
1. Check the gears for wear or scratches on
teeth, particularly in the chamfered area
of each gear.
2. The clip spring is fitted to gear (4) (Refer
to PAGE 20) and slides in the groove. A
too-tight or loose-fitting clip may result in
improper operation. If too loose, bend the
clip so that the friction increases, or re-
place clip.
Friction tension:
2.2 - 2.5 kg (4.9 - 5.5 lb)
P. Kick starter
1. Kick gears
Check the kick gears for wear or scratches
on teeth, particularly in the chamfered
area of each gear.
2. Kick clip spring
The kick clip is fitted to kick gear and
slides in the groove. A too-tight or loose-
fitting clip may result in improper ope-
ration. If too loose, bend the kick clip so
that the friction increases, or replace clip.
Friction tension:
1.2 - 1.7 kg (2.0 - 3.7 lb)
Crankcases and oil passages
Q.
1.
Check crankcases for cracks or other
damage.
2. Clean all oil passages and blow out with
compressed air.
R. Bearings and oil seals
1.
After cleaning and lubricating bearings,
rotate inner race with a finger. If rough
spots are felt, replace the bearing.
2.
Check oil seal lips for damage and wear.
Replace as required.
3-4. ENGINE ASSEMBLY AND ADJUST-
MENT
NOTE:
1)
All gaskets and seals should be replaced
when an engine is overhauled. All gasket
surfaces must be cleaned.
Properly oil all mating engine and trans-
2)
mission parts during assembly.
All circlips should be inspected before
3)
assembly.
Replace distorted circlips.
Always replace cotter pins and piston pin
clips after one use.
A. Shift
(Refer to PAGE 21)
Install shift forks, shift cam, guide pin, cotter
pin, guide bar, stoper plate and detent. Apply
LOCK-TITE to eccentric bolt.
NOTE:
Check for smooth and complete shifting after
installing transmission.
B. Transmission and crankshaft
1.
Rotate shift cam to neutral position.
2.
Install the transmission, bearings and seals
onto the upper case.
3.
Install crankshaft, seal and bearings.
NOTE:
Fit each bearing over each locating pin
and push the crankshaft into position by
hand. Each bearing has line or punch
mark which indicates the position of
mating surface.
29 -
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