STARTER CLUTCH
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SHAFT |
Remove the following:
- Right crankcase cover (page 11-5)
- Clutch (page 11-7)
Remove the reduction gear shaft and reduction gear B.
REDUCTION GEAR В
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GEAR HOLDER PRIMARY DRIVE I GEAR |
Temporarily install the clutch outer guide, needle bearings and clutch outer.
Install the gear holder between the primary drive and driven gears.
TOOL:
Gear holder, M2.5 07724-0010100 or
07724-001A100 (U. S.A. only)
Remove the primary drive gear bolt, washer, clutch outer, needle bearings, clutch outer guide and primary drive gear.
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BOLT/WASHER |
* CLUTCH OUTER
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Remove the bolts, gear holder, reduction gear A and 1 requqjion GEAR idle gear. |
Remove the starter clutch assembly.
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DRIVEN GEAR |
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NEEDLE BEARING |
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Check that the starter driven gear turns counterclockwise smoothly and does not turn clockwise.
Remove the driven gear and needle bearing from starter clutch outer.
Remove the snap ring and one-way clutch from clutch outer.
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SNAP RING ONE-WAY CLUTCH
CLUTCH OUTER |
Check the needle bearing for abnormal wear or damage.
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NEEDLE BEARING |
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Check the starter driven gear for abnormal wear or damage.
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Measure the driven gear boss O. D.
SERVICE LIMIT: 45.660 mm (1.7976 in)
Measure the driven gear boss I. D.
SERVICE LIMIT: 36.034 mm (1.4187 in)
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ONE-WAY CLUTCH
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Check the one-way clutch sprag for abnormal wear or damage.
Check the starter clutch outer sliding surface for wear or damage.
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CLUTCH OUTER |
Check the reduction gear A and idle gear for wear or damage.
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REDUCTION GEAR A |
Measure the reduction gear A I. D.
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SERVICE LIMIT: 12.050 mm (0.4744 in)
Measure the idle gear I. D.
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IDLE GEAR |
SERVICE LIMIT: 12.050 mm (0.4744 in)
Check the gear holder shafts sliding surface for wear or damage.
Measure the gear holder shafts O. D.
SERVICE LIMIT: 11.989 mm (0.4720 in)
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Check the starter reduction gear В and reduction gear shaft for wear or damage.
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Measure the reduction gear В I. D.
SERVICE LIMIT: 10.085 mm (0.3970 in)
Measure the reduction gear shaft O. D.
SERVICE LIMIT: 9.980 mm (0.3929 in)
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CLUTCH OUTER |
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BLUE PAINT ONE-WAY CLUTCH |
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Apply transmission oil to the clutch outer sliding surface.
Install the one-way clutch into the starter clutch outer with the blue paint facing out.
Install the snap ring securely.
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SNAP RING
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Apply transmission oil to the starter driven gear sliding surface.
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STARTER DRIVEN GEAR |
Install the needle bearing and starter driven gear.
Check that the starter driven gear turns counterclockwise smoothly and does not turn clockwise.
NEEDLE BEARING
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REDUCTION GEAR A |
Apply molybdenum oil solution to the starter gear holder gear rolling surface.
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BOLTS |
Install the idle gear and reduction gear A onto the gear holder.
Apply transmission oil to the gear holder bolt threads.
Install the gear holder assembly and bolts.
Tighten the bolts to the specified torque.
TORQUE: 18 N m (1.8 kgf-m, 13 Ibf-ft)
IDLE GEAR
GEAR HOLDER ASSEMBLY
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STARTER CLUTCH |
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PUNCH MARK |
Install the starter clutch while aligning its wide cutout in the splines with the punch mark on the crankshaft.
Install the primary Install the primary drive gear while aligning its wide drive gear with the cut-out in the splines with the punch mark on the
punch mark facing crankshaft. out.
PRIMARY DRIVE GEAR
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CLUTCH OUTER |
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BOLT/WASHER |
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GEAR HOLDER |
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Temporarily install the clutch outer guide, needle bearings and clutch outer. Insert the gear holder between the primary drive and driven gears. TOOL: Gear holder, М2.5 07724-0010100 or 07724-001A100 (U. S.A. only) Apply transmission oil to the primary drive gear bolt threads. Install the washer and tighten the primary drive gear bolt to the specified torque. TORQUE: 108 N m (11.0 kgf m, 80 Ibf-ft) Remove the clutch outer, needle bearings and clutch outer guide. |
Install the reduction gear В and reduction gear shaft securely.
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REDUCTION GEAR В |
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REDUCTION GEAR SHAFT |
Install the following:
- Clutch (page 11-12)
- Right crankcase cover (page 11-6)
