KICKSTARTER
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KICKSTARTER SPINDLE SNAP RING/ і ASSEMBLY Bl THRUST WASHER I t % « «« '-s |
Remove the following:
- Right crankcase cover (page 11-5)
- Clutch (page 11-7)
Remove the snap ring, thrust washer, starter idle gear and bushing.
Unhook the kickstarter return spring from the crankcase.
Remove the kickstarter spindle assembly.
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RETURN SPINDLE SPRING |
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PINION GEAR |
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SNAP RING |
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WASHERS |
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STARTER RATCHET |
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Disassemble the kickstarter spindle by removing the following:
- Return spring and collar
- Ratchet spring and starter ratchet
- Snap ring, thrust washers and pinion gear
- Pinion gear bushing
Check the return spring and ratchet spring for fatigue or damage.
Check the starter ratchet for wear or damage.
Check the kickstarter pinion for wear or damage. Check the kickstarter spindle for bend, wear or damage.
Check the kickstarter pinion gear bushing for damage or excessive wear.
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Measure the kickstarter pinion gear I. D.
SERVICE LIMIT: 22.05 mm (0.868 in)
Measure the kickstarter pinion gear bushing I. D. and
0. D.
SERVICE LIMIT: I. D.: 20.04 mm (0.789 in)
O. D.: 21.96 mm (0.865 in)
Measure the kickstarter spindle O. D.
SERVICE LIMIT: 19.97 mm (0.786 in)
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Check the starter idle gear and bushing for wear or damage.
Measure the starter idle gear I. D.
SERVICE LIMIT: 20.07 mm (0.790 in)
Measure and record the starter idle gear bushing
1. D. and O. D.
SERVICE LIMIT: I. D.: 17.04 mm (0.671 in)
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O. D.: 19.96 mm (0.786 in)
Measure the countershaft O. D. at the idle gear sliding surface.
SERVICE LIMIT: 16.95 mm (0.667 in)
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RATCHET SPRING
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RETURN SPRING |
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1 KICKSTARTER SPINDLE |
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COLLAR |
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Apply molybdenum oil solution to the kickstarter spindle spline area and gear rolling surface.
Install the collar aligning its gap with the spring.
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THRUST WASHER |
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BUSHING |
Install the thrust washer and pinion gear bushing onto the kickstarter spindle.
Apply molybdenum oil solution to the pinion gear inner surface.
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RING |
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PINION GEAR |
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SNAP |
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Install the pinion gear and thrust washer.
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Set the sharp edge of the snap ring facing out. Check that the snap ring is seated in the groove. |
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THRUST WASHER |
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Install the snap ring in the groove of the spindle.
Align the punch marks and install the starter ratchet.
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STOPPER PLATE |
Install the ratchet spring.
Apply transmission oil to the kickstarter spindle journal.
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Be sure the ratchet spring did not fall off the spindle during installation. |
Install the kickstarter assembly to the crankcase and rotate the spindle counterclockwise until the ratchet tab is clear of the stopper plate.
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RATCHET SPRING |
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RETURN SPRIN |
Hook the return spring end into the hole in the crankcase.
Apply molybdenum oil solution to the countershaft sliding surface.
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BUSHING |
Install the bushing and starter idle gear onto the countershaft.
IDLE GEAR
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SNAP RING |
Install the thrust washer and snap ring. Install the following:
- Clutch (page 11-12)
- Right crankcase cover (page 11-6)
THRUST WASHER
