Service manual

4-25
KICK SHAFT AND SHIFT SHAFT
REMOVING THE PRIMARY DRIVE
GEAR
1. Loosen:
• Bolt (primary drive gear) "1"
Place an aluminum plate "a" between
the teeth of the primary drive gear "2"
and driven gear "3".
REMOVING THE KICK SHAFT
ASSEMBLY
1. Remove:
• Kick shaft assembly "1"
Unhook the torsion spring "2" from
the hole "a" in the crankcase.
REMOVING THE SHIFT GUIDE
AND SHIFT LEVER ASSEMBLY
1. Remove:
• Bolt (shift guide)
• Shift guide "1"
• Shift lever assembly "2"
The shift lever assembly is disassem-
bled at the same time as the shift
guide.
CHECKING THE KICK SHAFT AND
KICK GEAR
1. Check:
• Kick gear smooth movement
Unsmooth movement
→Replace.
2. Inspect:
• Kick shaft "1"
Wear/damage
→ Replace.
CHECKING THE KICK GEAR AND
KICK IDLE GEAR
1. Inspect:
• Kick gear "1"
• Kick idle gear "2"
• Gear teeth "a"
Wear/damage
→ Replace.
CHECKING THE KICK GEAR CLIP
1. Measure:
• Kick clip friction force
Out of specification
→ Replace.
Use a spring gauge "1".
CHECKING THE SHIFT SHAFT
1. Inspect:
• Shift shaft "1"
Bend/damage
→ Replace.
• Spring "2"
Broken → Replace.
CHECKING THE SHIFT GUIDE AND
SHIFT LEVER ASSEMBLY
1. Inspect:
• Shift guide "1"
• Shift lever "2"
•Pawl "3"
• Pawl pin "4"
• Spring "5"
Wear/damage
→ Replace.
CHECKING THE STOPPER LEVER
1. Inspect:
• Stopper lever "1"
Wear/damage → Replace.
•Roller "2"
Rotate outer race with a finger.
Rough spot/Seizure
→ Replace
the stopper lever.
• Torsion spring "3"
Broken
→ Replace.
CHECKING THE PRIMARY DRIVE
GEAR AND PRIMARY DRIVEN
GEAR
1. Inspect:
• Primary drive gear "1"
• Primary driven gear "2"
Wear/Damage
→ Replace.
INSTALLING THE STOPPER
LEVER
1. Install:
• Torsion spring "1"
• Stopper lever "2"
• Bolt (stopper lever) "3"
•Align the stopper lever roller with the
slot on segment.
•When installing the stopper lever,
make sure that the torsion spring is
in the position as shown.
Kick clip friction force:
0.8–1.2 kg (1.8–2.6 lb)
Bolt (stopper lever):
10 Nm (1.0 m•kg, 7.2
ft•lb)