9. KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY MX’er 50 9 KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY SERVICE INFORMATION ...........................................................9-2 TROUBLESHOOTING .................................................................9-2 9 KICK STARTER ..........................................................................9-3 DRIVE BELT...............................................................................9-7 DRIVE PULLEY .............................
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9. KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY MX’er 50 SERVICE INFORMATION GENERAL INSTRUCTIONS • Avoid getting grease and oil on the drive belt and pulley faces. SPECIFICATIONS Item Drive pulley collar O.D. Movable drive face I.D. Weight roller O.D. Clutch outer I.D. Driven face spring free length Driven face O.D. Movable driven face I.D. Drive belt width Standard (mm) MX’er 50 Service Limit (mm) 20.01 _ 20.025 19.97 20.035 _ 20.085 20.24 13.0 12.4 107 _ 107.2 107.5 98.1 92.8 33.
9. KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY KICK STARTER MX’er 50 Left Crankcase Cover LEFT CRANKCASE COVER REMOVAL Remove the left crankcase cover bolts, left crankcase cover and dowel pins. Inspect the left crankcase cover seal rubber for damage or deterioration. Bolts Kick Starter Spindle KICK STARTER SPINDLE REMOVAL Remove the kick lever from the kick starter spindle. Remove the circlip and washer from the kick starter spindle.
9. KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY MX’er 50 Return Spring Remove the kick starter spindle and return spring from the left crankcase cover. Remove the kick starter spindle bushing. Kick Starter Spindle KICK S TARTER S PINDLE INS PECTION Inspect the kick starter spindle and gear for wear or damage. Inspect the return spring for weakness or damage. Inspect the kick starter spindle bushing for wear or damage.
9. KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY MX’er 50 Kick Starter Spindle Forcing Part Inspect the kick starter spindle and driven gear forcing parts for wear or damage. Kick Starter Driven Gear Forcing Part Friction Spring KICK STARTER INSTALLATION Install the kick starter spindle bushing and return spring onto the left crankcase cover. °ØIf the hooks of the return spring can not be installed properly, use a screw driver to press them into their locations respectively.
9. KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY MX’er 50 First install the washer and then the circlip onto the kick starter spindle. Install the kick lever. Washer Circlip Seal Gasket LEFT CRANKCASE COVER INSTALLATION First install the dowel pins and then the seal gasket. Dowel Pins Install the left crankcase cover and tighten the ten bolts diagonally. Rear Brake Cable Clamp °ØFor drum brake, note the location of the brake cable clamp and install the rear brake cable in place with the clamp.
9. KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY MX’er 50 DRIVE BELT Remove the left crankcase cover. INSPECTION Check the drive belt for cracks, separation or abnormal or excessive wear. Measure the drive belt width. Service Limit: 16.5mm replace if below °ØUse specified genuine parts for replacement. REPLACEMENT Remove the left crankcase cover bolts and left crankcase cover. (!9-3) Hold the clutch outer with the universal holder and remove the clutch outer nut and clutch outer.
. KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY MX’er 50 Clutch/Driven Pulley Remove the drive belt from the clutch/ driven pulley. Drive Belt DRIVE BELT INSTALLATION Turn the driven pulley clockwise and lift it up to expand the drive belt groove and then install a new drive belt. Drive Belt Drive Pulley Face Set the drive belt on the drive pulley. Install the drive pulley face, then tighten the drive face nut.
9. KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY MX’er 50 DRIVE PULLEY REMOVAL Hold the drive pulley with the holder and remove the drive face nut. Remove the drive pulley face. Drive Face Nut MOVABLE DRIVE FACE DISASSEMBLY Remove the movable drive face and drive pulley collar from the crankshaft. Drive Pulley Face Movable Drive Face Drive Pulley Collar Remove the ramp plate.
9. KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY MX’er 50 Weight Roller Remove the weight rollers. Remove the weight rollers. Check each weight roller for wear or damage. Measure each roller O.D. Service Limit: 12.4mm replace if below DRIVE PULLEY INSTALLATION Install the drive pulley collar and movable drive face onto the crankshaft.
9. KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY MX’er 50 Install the drive belt on the crankshaft. Install the drive face, then tighten the drive face nut. Torque: 3.5_ 4.0kg-m °ØKeep grease or oil off the drive belt and drive pulley faces. Drive Face Nut Drive Pulley Face Starter Pinion STARTER PINION REMOVAL Remove the left crankcase cover. (!9-3) Remove the drive pulley. (!9-9) Remove the starter pinion cover. Remove the starter pinion.
9. KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY CLUTCH/DRIVEN PULLEY MX’er 50 Clutch Outer 14mm Clutch Outer Nut CLUTCH/DRIVEN PULLEY REMOVAL Remove the drive pulley. (!9-9) Hold the clutch outer with the universal holder and remove the clutch outer nut Remove the clutch outer. Universal Holder Clutch/Driven Pulley Remove the clutch/driven pulley. Remove the drive belt from the clutch/driven pulley.
9. KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY MX’er 50 Remove the seal collar. Seal Collar Pull out the guide roller pins from the driven pulley and then remove the O-rings and oil seal from the driven pulley. Driven Pulley O-rings CLUTCH/DRIVEN PULLEY INSPECTION Inspect the clutch outer for wear or damage. Measure the clutch outer I.D. Service Limit: 107.
9. KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY MX’er 50 Check the clutch shoes for wear or damage. Measure the clutch lining thickness. Service Limit: 2.0mm replace if below Measure the driven face spring free length. Service Limit: 92.8mm replace if below Check the driven face assembly for wear or damage. Measure the driven face O.D. Service Limit: 33.94mm replace if below Check the movable driven face for wear or damage. Measure the movable driven face I.D. Service Limit: 34.
9. KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY MX’er 50 Inner Bearing DRIVEN PULLEY FACE BEARING REPLACEMENT Check the needle bearings in the driven face and replace them if they have excessive play, damage or abnormal noise. Drive the inner bearing out of the driven pulley face. Remove the snap ring and drive the outer bearing out of the driven face. Outer Bearing Bearing Outer Driver Drive a new outer bearing into the driven face with the sealed end facing up. Seat the snap ring in its groove.
9. KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY MX’er 50 Bearing Driver Pilot Drive in a new needle bearing into the driven face with the mark facing up CLUTCH/DRIVEN PULLEY ASS EMBLY First install the movable driven face onto the driven face. Then, install the guide roller pins, O-rings and a new oil seal. Driven Pulley O-rings Guide Roller Pin Install the seal collar.
9. KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY MX’er 50 Set the driven pulley, driven face spring and clutch assembly onto the clutch spring compressor. Compress the tool and install the 39mm drive plate nut. Tighten the 39mm nut to the specified torque. Torque: 5.0_ 6.0kg-m Clutch Spring Compressor Clutch/Driven Pulley CLUTCH/DRIVEN PULLEY INSTALLATION Install the drive belt on the clutch/driven pulley and then install the clutch/driven pulley onto the drive shaft. Install the clutch outer.
