Removal Of Muffler; Removal Of Kick Starter Lever Assy; Removal Of Drive Pulley - TGB Hornet 50 Service Manual

4-3-1 Dis-assembly of Engine:
( Muffler, Kick Starter Lever Assy , Drive Pulley Assy .)

1. Removal of Muffler

A. Hold the brake cable and lift the body until the rear
carry bar touch the ground.
B. Remove two bolts connected with the engine.
C. Removel one bolt connected with the rear frame.

2. Removal of Kick Starter Lever Assy:

A. Remove the hexagon bolt (15)of kick starter lever
assy (16) and remove the kick starter lever assy.
B. Remove the fixed screw of clutch cover.
C. Remove the Spring (17) of kick starter shaft.
D. Remove the kick starter shaft (18).
E. Remove the bush (19) of kick starter shaft

3. Removal of Drive Pulley:

A. Remove screw (1).
B. Remove spring seat (2).
C. Remove spring (3).
D. Remove washer (4).
E. Remove the left hand starter assy (5).
F. Remove the RH starter (6).
WARNING ¡ G Because it is LH thread inside the RH
starter, it is necessary to use deep bush while
removing (to avoid contact with the crank shaft),
and remove the RH starter by using pneumatic
wrench turns to right hand. If it turns to left hand,
the wrong direction, it will damage the crank shaft
easily. Special Tool: GA5000051F36.
¡ ·
If manual wrench, instead of pneumatic wrench, is
adopted, stop tool will be needed.
Special Tool: GA5000051F35.
A. Remove Movable Drive Face (7).
B. Remove V-Belt (8).
C. Remove Drive Pulley Assy (9) and Spacer (10)
¡ · Press the Movable Drive Plate and Drive Pulley
Face while removing the Drive Pulley Face Assy in
order to avoid the roller to stand up.
D. Disassembly of Driven Pulley Face Assy: Remove
screw (11), Movable Drive Plate (12), roller (13) and
guide block (14).
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