HUSABERG ENDURO FE 400 User manual

INDEX
GENERAL INFORMATION
LIMITS
OF TOLERANCE
MAINTENANCE SCHEDULES
FUEL SYSTEM
ALTERNATOR & IGNITION
LUBRICATION SYSTEM A OIL FILTERS
B REED VALVE
C
OI L PUMP
TRANSMISSION A CLUTCH
B GEARSHIFT MECHANISM
C KICKS
TA RT MECHANISM
CYLINDER HEAD A VALVE ADJUS
TM E NT
B DECOMPRESSION ADJUSTMENT
C WATER
PUM P
0 SERVICING OF CYLINDER HEAD
CYLINDER & PISTON
CRANKS
HAFT & GEARBOX A REMOVAL OF EN
GI NE
B SERVICING OF CRANKSHAFT &
GEARBOX
C INSTALLATION OF ENGINE
ELECTRICAL STARTER
SPEC
IAL TOOLS

2
GENERAL INFORMATION
SUBJECT/MOD EL
Engine rype
Displacements
Comp r osslon 1alio
Star1 system
-----
Oocomp1e-ssion system
SPECIFICATIONS
ENDURO MOTOCROSS ELDURO DESERT
Liquid coo&ed . 4·stroke single cy11nde1, SOHC-4 \'8.f\'CS
----
400-mod:els : 399ccI Bore 92.0 mm x S1ro ke G0.2 mm
501 ·models; 501 ccI Bo re 95.0 mi nx Stroke Ｗ ＰＬＷｾ ｭ ｭ＠
600·mod els; 595 ccI Soro 95,0mi nx S1roke 84 .0 mm
4 00 - mO<le ls : 1 1. 6: I
50 1· modcls: 1 1. s. 1
600-mod cls: 11.2 :1
Kick statter Ef(lcttical '" Md kiek ｳｴ｡ｲｴｾｲ＠
Fully oucoma11e •Yi- activale<f b>J Ille Fully a..-at.c syslemacti>""ed by tho
camshafl plus an additional system cam.shalt
acwa!Ald by 111e - sraner
---- -----
D<>cctnp. cable"'""""'°"
Valve clearance
Lubticatlon
E1 l.g1 ne 0t l
2mm#.1 mm
----
In take: o,1o mm
E
J<haustO.IOmm
Not avaiai1:Jite
0 1'bit atlpump and ree dv(!lve oontroll0d lublico 1100
Oil...cOO!e d pis ton alld conno C11 ng rod
Aop la ceable n1icro filter and v 1ashobto oil ｳ｣ ｮＮ ｾ･ｮ＠
1 .0 lltr• Syn lhelic SAE SW·SO AP I SGICF (minimum SAE ISW·S O)
----
I gnition SEM. CO i, OFC',,,; Dynamic Forco '- Cc '-'- n __ tr -- 01 ___ _
Spark plug NGKCll E
0. 7mm
12V / 70• 70W NoHwailallle 12V / 70+ 70W 12V / 70+ 70W
Spotk plug gap
A1111natot
Ccolani
ＭＭＭＭＭｾ＠
1.3 kite of SOC' .. Atti•lreete. v.'ith CXHTOSiOn inhib«OI, and 50% watei
------
Cluteh __ _
OIUlch cab le clearance
GOQ l' bOX
tRatios 1
s1 geat
2nd gear
3rd gear
4th gear
5th gear
6th gea:
Pt.mary 1ransnission
6·spoo<IWR
13,134. 2.6 15
1 7130 -1,705
20127 • 1,350
Zl/24. 1, 043
25122. 0.880
27/20. 0.741
7 tric:tion -and 8 ma11ng p&a.101 in o-a bath
1-2mm
4 or (6)- speed CR 6-SpO<ld WR 6-speed S·W R"
151 32. 2,1 33
1Jf.l4 • 2.6 1s 1
5/32. 2, 1 33
18128 · I .SSS
1 7130. 1,765
1812 8 · I .SSS
20/25 . 1,
250 20/27 • 1, 350 20!25 • 1,250
23/24 . 1,043 23/24 • 1, 043 23/24 • 1,0 43
(24.122 . 0,917)
25122 •0. 880 25 l 22 . o.sso
(25121 . 0.840) 27 / 20. 0,741 27/20. 0.741
"h:Uing Er0.roH
SpurgeatS
-----
Aa110 29178. 2 .690
Secondary transm . ssio n 520 0 -1i ng oh a1n
Ratios 501 /4 -sp eed 15/42 . 2 . 600
151 42. 2,800
1
3146. 3.692 13146 • 3.692 ＱＳＯ ｾＮ＠ 3. 692
600/4-speed
1
400/6-speed
-+---
1 51 4 8. 3.200
(13/48 . 3,692)
50 1/6-speed
600/6- specd
Catbure u oc
(std. j0H1ng see nex! page
PJr i11ration
Fuel
E 1< haus1 sys tem
1 5/48·3 . 200
( 1514 8. 3,200) I
S/48. 3.200
(15/42 . 2.800) 15/48 • J,200
400-models: Oel lorto PH M 38
501 · & 600-models. Oollo<IO PHM 40
151 48 . 3, 200
ＱＵＯ ｾ＠ . 3 .20 0
lluo l Spon USA · FS 600: Edelbtock ｏｷｬ＼ｳｩｾｲ＠ ＳＸ ｾｾｾＭ
0oWle loom filO<S Single loam liter OoWle loom fillMS Dot.dlle toam file<s
lnduding Ellduro II
RON 98 (ocmno)
Sl ain less sleel pipcs, 211l lo 1 coll&c: or , a1 umlniumfs1aintess s1cc l silencer
U S-vcrol ons ol EndlXO. En dl. ir o 11 , Cklu-·o and Doson equpped v.i th spa rk a rrestet

GENERAL INFORMATION
CARBURETTOR STD. JETTING$
MOO EUSUBJ ECT
---
Main
jet
ENOURO :...... __ ｆＭＧ ｅ ＺＮＮＴＰＰＭＢＢＧ ｾＭ ＲＱＰ＠
Noodlo NcedSe tleedle
Je t cUp
DR 272 K 35 "3
FE 501 195 OR270
_:...:...... __ _:_
K5 1 #3
F E600 195 DR26 8 K5 1 #3
EN DURO USA FE400 195 0 0
KSt
#3
FE 50 t 19 5 0 0 K51 #3
-
F ESOO 195 0 0
K5 1 •3
ENOU
RO II FE 400 S 175 0 K5 1 •3
Pilot
jet
55
45
35
55
40
40
SS
Thloalo Float Start Mixture
valve jet screw
so 300 45 21Ulro
•O 300 45 Ｑ ｾＱｵＡｲＧｉｓ＠
ｾＡ＠ ｩ ｾ＠
00 45 1
71 l.&'l'lS
00 45 1!hl.rr'$
45 1 %0...WS
-
0 45 Ｑ ｶ ｾ Ｑｵｮｳ＠
so 300 •s u; iums
'
R27
R27
R27
A 268
R270
ＧＭＭｾＭ
FE 501 S 172 0
K5 1
•2
45
4() 300 = _ ｟ＮＺ Ｔ ＺＮ Ｕ ｟ＮＮＺ Ｒ ＮＮＺ Ｐｊｭ［ ［ＮＮＮ｣Ｚ ｾ＠
FE600S 172 OR272 K51 _:_ _ _.:.:_ _ _: so
13
45
300 45 ""' "'
｟ＳＰＰ ｾＭＭ 󰿃Ｕ＠ __ 2..,.,,
ENOUAO II USA FE 400 S 190 OR 270 K35 in
52
FE-'-'-50 '- l_S:......_1_ 72 :...... OR 272
K51
13 35
Ks1 #3
35
SS MOTOCRO
l E LOURO
.F _E _ 600 __ .S.1 .72 DR270 t'-'-:......,_; :.:.._ _
R268 K51 #3 55 FC400 175 D
F C501 172 0 0 K 51
FC
600 172 D 2 ' K 5 1
R27
A
27
R
266
ELOUROUSA
FE 4 00 E
-
FE oOI E
F E600E
1
FE 4
00E
FE501 E
FE 600E
DESERT USA FX <00 E
1 95
0
0
195 OR 27
195
OR26!1
195
195
195
195
OR270
OR270
OR270
OR270
F XS01 E 195
OR270
DR270 FX 6 00 E 1 95
-J'--
DUAL SPORT FS600 E
K35
K 51
K
51
K 51
K51
K 51
KS1
K 51
K 51
K6
#2 45
•3
45
13 52
»3
45
• 3 35
#3 55
#3
4()
#3
"°
#3
55
•3
40
•3
40
19 out
TORQUE VALUES
SUBJECT TORQUE
----
Intake manifold scr e'l•'S 3 Nm
so
40
40
50
40
50
S(I
40
40
so
40
40
50
40
4()
300 ｾＭ ＴＵ ｟ Ｍ __ 1;; _ ..,.. _
300 "5 ＱｾｕｔＧＶ＠
300
45 1\;urG
300 45
21UnS
-
300 45
Ｑ ｾ ｴｵｮＧｊｓ＠
300 ;15 ll ? tums
300 45
1l!i b.u m
300
45 l Y..b.mS
300 45 11Slur6
300 45
ll'UT6
300 45 1Y..UT6
300
45
. '* """"
300 45 Ｑｾ｢ＮＮｭ＾＠
300
45 I1i;o.ms
NOTE
-----
0.J titer coo1er I Water pump cover sae-.v& 5 Nm
()I punp CCM>r I Ree<! """"' S<:rcws SNm --------' N>Pty a ttv- liq<.id
Valve Inspection """" screws 5 Nm
State< sa.... _8_ Nm _____ AW1Y a 1hrc3dlod< liqlnd
Crankcase I T roostn1s sion cover ser cvlS 1ONm
Cyhnder head ( tvt6 ) scrcv/S
Exhaus t ptpo scrmvs
Goarshllt lever scre-.v
-'-'--'------
Kick S 141 ft lever sere'"'
Val ve cover :. •C ::':. cw c: • :...._ __ _
1 0N m
1 0Nm
10N m
10 Nm
1
0N m
12 Nm
App
ly a thr eadlock li qu id
Oil drain pl ug / Spa :.. rk :.!p :C l u"g '- --
Val\le adjus1ment lock nuts 12Nm
-"-----
Upper liming sprocket screws
ｾＮＭｳｴｵ､＠ nuts
Flyv.11 ... nut ____ _
25Nm
44Nm
SO Nm
BO Nm
tv14
Lot1 ·hand thread
MS M6
MS
M15
Primary gea1 '"heet ｮ ｾ ｵＺＮＺＮｴ＠ ----
1 Standard t orq ue va lues
ＭＭＭＭｾ＠
6Nm 8 Nm 10 Nm 25 Nm ! 13 SNm
3

1 GENERAL INFORMATION
Please read
and observe the following:
Warning
If the engine m ust be r unn ing during any ma intenan ce, make s ur e that t he ar ea is
proper
ly ventilated. Never run l he en gine in a closed area thou gh the ex h aus t fumes
are posionous and thus hazar
do us to your hea lth and life if not properly ventilat ed .
Warning
Although the battery is of a seal ed construction. pleasetake care.The elect ro lyte co ntains
sulf
ur ic acid and you must protect yo ur eyes, sk in and clothing if such fluid is assumed
to
be l ea king or l ik ewise exposed. In case of contact. wash and flush thorou gh ly with
wa ter a nd contact medical help if needed, especially ifyour eyes have been exposed to
the fluid.
Warning
Fuel is ex tremely fl am mable a nd explosive under certain conditions. Do not smoke or
expose the fuel to open fire or spark
s.
Service condit ions:
1. Alwa ys use origi na l Husaberg pa rt s.
2. Us e the special Husaberg tools when required.
3. Install n
ew gaskets, o-rings, circli ps etc whenever possible.
4. Always clean all parts thoroughly before assemb
ly .
5. All scre
ws, nuts and bolls e tc . are in the metric system. Do not u se incorrect tools.
6. Never warm any
al um inium part for mo re than 30 minutes due to the heat tr ea tmen t.
q. 0 This symbol means that it is possibl e, although not always recommendable,
v v to perform the specific service without re moving the engine ou t of the frame.
The material and information included in this
'No rkshop Manual are all of the latest
ed it io ns available at t he time of the pr inting.
Husaberg Motor AB reserves the right to make changes r
eg arding the products at an y
time \•1 ithovt pr io r no ti ce.
This ｾｖｯｲｫｳｨ ｯｰ＠ Ma nual is subje ct to co rrections witho ut prior notice.
No part of this Works
hop Manual may be r ep r od uced without written permission
｡ｊｾｦｩｬｾｾ ｶ ｾｅｾ＠
E nd ur ovage n, S-695 72 SWEDEN
www.husabe
rg .se
[e-mail]

2
Maximum
ad ial pis
0,05 mm
LIMITS OF TOLERANCE
Va l ve sea t
ｲｩＮ ｾ｡ ｸ ｩ ｭｵｭ＠
1, 8 mm
0, 7mm
l'+- -K::i- -+!Max imum dev i ation
O,OS mm
92 mm· ｪ］Ｚｾｾ］ｾ＠ Place ot max .
!in, 9·1.86 m r I diameter
95 mm ·
f>lin . 94 , 88 mm
·•-
h!aximum
radial p lay
0,
04 mm
l1!ax imum
radial play
0,04 mm
YEL/YEL (+) - BLU (-) =<1,0 Ohlll
RE D(+). BL K (·) =3 kOhnl :1:1 ｯｾｾ＠
GRN (+) - BL K (·) : 168 Ohm ＺＱＺＱＰ ﾰ ｾ＠
5

•
MAINTENANCE SCHEDULES
Enduro and Elduro models
Please obsenle: Rid in g under hard cond tt io ns d<!mands more frequent maint en an ce
SUBJECTI HOURS
10 20 30 '° 50 60 70 80 90 1001101201)()140150160170180190200
Engine oil
0 11 &o 1een
O!I microl il !e r
Oil pump 1nd. feed va1 ... e
Coofan1 liquid •
Sjlotk P"9 ( lfld. cap )
... _odlgn< ........
v- dea!ar<:C
-----
Va l \10$ inol . guides & sea ltngs
Ti ming Cl la in i l'IC I. ｾ ･ｮ ｳｩｯ ｮ･ ｲ＠ t
Pialon !net rin gs & pin
Cy linder
ConnCC11ng ro<J
Crankahah pin
-'-----
Clutch mechanism incl. discs
Cort>urottot •••
°'"l>h<agm fl><ll ｾ＠
ｾｲＱ＠ mect8lism
Goars t 11tt mechan is m
E l: Frca.\•hocl mechanis rn
Connoetin9 rod
CranksMh
----
Gearbox main shaft
-------<
a
ｾＭｲｹｳｨ｡ｦｴ＠
-'------+
Sl>hdrum
Comshah
-----
Out.ch pressure p6ie
Klcksta r1 mecha n ism
----+--+
lnlormodlate ｧｾ｡ｲ＠ vlheel
EL: lnterm cdia1c sh aft
EL: Coun t ee ba lancer
Connecting rod
-'----
Roc:lcenl mis
-----
Kidc$tar1 .... ft
Ck.<Ch Shall
REGULAR
..a ._ a_..a .._. a_ - 1-..
1 1
BEARINGS
I
i '
BUSHINGS
C: Clean • I: Inspect • R: Replaco
a
' ｾﾷＱｦｴｸｩＧｮｵｴｮ＠ 12 • 'OOl'llhS inlei"\'ill • •• Oeanwl'IOl'l(Mlf lhO 019 1 \0 has been\\tish£11.1 • •• • l(B): [spocia1ynoode ard n=ede jet

MAINTENANCE SCHEDULES
Motocross and Desert models
ＱＴＡＪ󱁍ｴｩﾷ ｬﾷ ｽｴﾧｗｬ［ｍｬＡＬｴ Ｎ ＱＱＱＬＱＮｭ Ｌ ｰＱＺＮＱｧＮｊＬｊＮｭｴＮｬＬｾｪＮＱＴＬ Ｌ ｅｊＬｴ＠ .. ｾＱ Ｎ ＬｲＮｊｴﾧｬｴｻＮＡｩＡﾧ＠ .. i"f;Jfui§ .i; !, tgs
REGULAR
Eng ine oil
0 11scr een
Oll m>c rofilte :_: r _____ _.__J_j_-!- -11""- -1-1--
0 il pu mp i ncl. re ed va t va
Coolan1 li quld •
Spark p
lug (In d. cap)
Valves in cl . gui de s & sool i ngs
Timing chain incl. tensiorier
Pis
to n incl. rings & pin
Cy
li n(ler
Connecting rod
ＭＧＭＧＭＭＭＭＭＭｬＮＭＭＭｬＭＭＱＭｾＭｬＭＭｬＭＭＭＱＭｾＧＭＭＭＧＭＭＱＭＭＱＭＫﾭ
CrankSl)alt pin
Clutch mochan.ts fn I ncl. d.scs
Carburettor •·•
ＺＺＺＺＮ ｾｾｾｾｾＭｌｾＭｌＭＭＱＭＭ
0 iaph mg m ruel pump
Kick.start mcchan ls o1
Gearsh ift mech ani s1 n
E L: F ree •1 fhe-.e t mechanism
ＺＮＮＺＮＮＺＺＮＺ｟｟ ｾＮｊ｟Ｎｊ｟｟ｊ｟｟｟｣｟｟ｊ｟｟｟ｊ｟ｾＭＭＧＭＭＭＧＭＭＭＧＭＭＧＭＭＭＭＧＭＭＭＭＧＭＭＭＭＧＧＭＧＭＧＭＧＭＢＭｾ＠
ｾ ｮ･｣ｩｩｮｧ＠ rod
Cr· anl<Stlaf!
Gearbol( nlain sha ft
ｾ ･｡ｲ｢ｯｸ＠ seoondarii shaft
Shifl d tum
C<lms!)afl
Clutch pressu re plate
Ｑ
ｾ＠ Kickstart mechanism
lnt
ernY.!dia le gear \\• heel
1 E L: lnt e1med l a1e sl\a lt
1 EL: Counter balancer
Rcd<.erarrns
ｋ ｩ ｾｴ｡ ｲＱ＠ shaft
Cl ulC I) Shafi
BEAR I NGS
.
. .L !
..
•· t
..
.
'
I
"
ｾ＠
I
ｾ＠
. .
BUSHINGS
C: Clean -I: Inspe ct • R: Replace
-
Ｇ ｐＮｩｾ ＢｙＡ ｵ ｲｮ＠ 12 m::fllhsinletval • •• ｃＧ･｡ｮｶＡｬＧｬ･ｮ･ｬＮｾｬｨ･＠ eorjnel"(\$ 00Ccl \ \;,l$1 '\00 . ... l(R): Especki ty nood'e ard ne ed'e je:
7

•
4
FUEL SYSTE M
CA RBURETTOR
Dell c: to PH r., 1 38 /40
Remove ih e carbufeUo r fr OJ n the int a.J<e mani!cid aruf
theahli
1!A r tu be .
Unscrev1 !ho l>c :t (Fig . 4 A· 1) ho lding tho fuel ul f el
pipe (Fig. 4A ·2) and the fuel fi lter (Fig. 4A ·3 ).
Thoroughlyciean the fil ter and the surrwf' -. ding areas.
Uns cr ev1 th c ch oke lever (Fig. 48 · I) iro1 n {he chok e
housing {Fig. 4B·2). Thcroughly clearl .an d lu br i cate
t he c hoke lever: bo th t he lev-er shah as \veil a s the
piston, (lnd the inside of t he 1 )-0US i ng .
Check
tha t o.11 three scre-. ,·s are ias te .1cd( Fi g.4B·3).
Check the r, osi t io ns of t he Idli ng sc re •1 1(Fig. 4S·4)
(Ind the mixture scr ev1 (F ig . 46 · 5) according to Ille
instruchons in t he Ov•ne r's t .10.nu al.
See Section 1 fo r s ta nd ard ie!tings.
Oi sm an ue lhe throttle coverand c hec.l< tileo-ri ng lor
any damage or detoricta hon ( Fi g. 4C· 1).
U nscfGI\ \' th e v1 ire nipple (Fig.4C ·2) fr ·om lhe throttle
(Fig. 4C·3) and disconnac- 1t he v1 ire (Fig. 4C "4) a1 ld
t he spri r. g.Check the t hr ottle fo f any deterioration.
Pu sh ovt tho r.eed!e and check !he condi tion of the
needle. especially at the s urfaoo as shcv 11 n (Fig.4 C-S }
and ai t he needle c li p po $it ion ( Fi g. 4C·6).
Cheek t he inner of the •1 1i ro l ll be. especia ll y at \he
posiiion
shc.,..· n (Fi g. 4C · 7) .The •1.• i re mighl ctea!e a
f ough jag into the inner of the tube and thuscausi ng
damages to a ' "i re.
C- re an the ins id' e of tho ca1bu r en or( Fi g. 4C·8 }.
Make ｳ ｵｮｾ＠ thal both of the ventilation lu bes are
positioned as
shov1n (Fig. ｾｃ Ｍ ＹＩＮ＠
u ns c,e ·1.· t he bottom plug (F ig. <I D· 1) and remove
the iloat chamber ( Fi g. 40 ·2). Check th e seali ng of
!hep!
ug and the ｾｩ ｮｧ＠ oft he d lam ber for a;iyd amages
or dete;ioration.
Che ck the carou;cuor floats (Fi g. 40 -. 3) fo r any
leakages.
Check and cl ean the maiojet (Fig. 40- 4). the ne ed le
jet (Fig. ·1
0·5 , posit io ned underne a ll ) lhe ma in j e1
seat). th o flea! va l ve and the float valve scat (F ig.
40 -6), lhe pilot jet (Fig. 40 · 7) a 11 d th e s1a rt je t {Fig.
40 ·8 ).
ｾ Ｍﾷ＠
¢
ｶＮ ｾ ｾ＠
.
ｾ＠
ｾ＠
ｲ ｾ󰿃ＭＺＺＭ
c-:::
ｾ＠
\ Ｍｾﾷ ﾷ＠
c:::
"
..
6
.
•
¢
.
& <· ··<D ···
Ｎ 󰿃ﾷ ﾷﾮﾷ ﾷ ﾷｾ＠
Fig.
AA
'"
ﾷｾ＠
<C
ｆ ｾＮ＠
· lD

4 FUEL SYSTEM
Chec k and cl ean th.e m ixtu 'eset cv1 (Fig .4 E·1). Check
lheocndil
ioo of theo-- 1in9, the'"asher an d the spring.
Repeat
the che ck regarding the idli ng S CfC\\' ( Fi g.
4E -2).
Uns crev1 the l'h'O scre\vs of tho venturi {Fig. 4E· 8)
and remove the venturi.
By usi ng comp t essed ai t, de an off the air du cts ( F'l g. .
<tE -3, 4, 5 and 6). Proceed \vi th the need!e j e1 tube
(F ig . 4E· 7) .
Check ｾ ｨ･＠ o ·r ing of the venturi (Fig. 4E·8) i or any
dan)age ordeteliot a! ion.
T<1. '0 versions oi float chambers are being used in
the production: Type A and T ype B. This be i ng Ille
ｯｮ ｬｾ ﾷ＠ di fference besides the va rious con fi gu rations
of the fettiilg dependr
ng on nlodel.
Check and clean the airfiltcrs accotding to the
1n ail l!eoa n c:: e schedule or more o ften if used under
hard conditions.
Check the airfiller tube ( Fi g. 4G · 2) fo r any cracks or
dcterio< a.tion.
Check and clean the inn.e r of th0diaphragm pum p.
Check and clean t he upper n.:bber segr nc nt (Fi g. 4H ·1 ),
the IO\\ •cr (Fig.4H·2) and t h& plastic diaphragm( Fi g.
<IH -3).
Check espe ciall\' Ille surfacesol t he 1• 1;oreeds ( Fi g.
4H·4) tor any contraries.
.
y y
'.
? 0
0 0
1 t f' 2
'f 37 Ｑ Ｍ ｾ＠
29 ＳＰ
Ｓ
ｾ Ｒ＠ i,,, 35 36 ｾ ｾ＠
",::- •• 33 "wfS
24 "'" 28 344'\. ｾ＠ 8
25 26 27 ｴＢｾｊＺＧＭ󰿃Ｇ＠ 12 '-.
52 ｾｾｾ＠ ｾ＠ CJ 11 10
23 ! '' 1 13 1... -9
50 ' 22 I 14
46 47
21 _.,,.. 15 •• 1t ". 45
51 20 ｾ＠ ｾ＠ 16 f.
19 ａ ｾﾷ Ｑ＠ s1 17 B .re: 43
cp
.
.
39 . ｾ＠ 40 42
38 -- . 41 48 ｾ＠ 49
•
(j)
.
Fi !J.
,,
Fig .
"
F19 .
· lH
•

10
5 ALTERNATOR & IGNITION
DISASSEM B LY OF AL TERNATORllGNmON
ｾｴｨ･＠ thfOO SCte'A'SQf ｴｨ･ｾ＠ OOV9t and
romcwe the cover includWlQ the stator II !heStator 1s
going lO be drsmounted disconnocl the •11.-i ri ng
hainessoflhe atlemat o(Jigru bon l rom lho mai n\ vinng
ha.moss and tt\e ign it ion coil.
AU 8Ch lhe fl\f\vtlC el hol der {Fig. SA· I. A ttlCIO No.
27 0030 -0t) ir,to one of !he slots In the ｈｹｾ ｶ ｨｯｯ ｬ＠ a.n d
by u sf ng t\vo of lho flyv lheel oove r scrov /S (Fig. SA·2),
Un scro v1 the JI Y"•he el nu t. c lock.\v1se (Fig 5A·3), and
1e rn ove the nu1 .
Re1easo lhO llywheel from lhe cranl<Shatt by using
U1'I lywheetpuller(Fog.5B· ｉＮｾ＠ No 270028-01).
Be car oful not to lose iho woodru11 key (F09 . 50·3).
Vn$Cro v1 lhe lhr ee sc revtS of lh& suuor {Fig 5C·1)
and remove tho sL a!or.
Ul he st ator Is presu med to be ol m a11un c Uo n oh ec k
ooC: ll •1.• l re of l he st ato r •• .., ith ｡ ｲ ｾ＠ ohmmeter;
flua!•l
ｾＬ ｕｬｽｹｾ＠ (·}
Yilllllt
RG<I
Blaek 3k0hmsl0%
Gt-
Blaek 168Ohm it. I 00' ..
YelowfYclow ' Blue <1.00hm
• Thi) 1v.'O yellow \\•i res 10 be connacted in paraltct
Check lhe inside ot Lil e llyv1h eel (Fig. 50 ·2). !he
,
.., OOdfu ff key ( Fi g.5 0-3 ) . the s tato f (Fig. 50· 4) and
thoo il se al oflhc cmnk:Shafi (F ig. SC-2) for a ny damages
Of d0 10 r10nl!ion.
Thoroughly clean tf'le inside oi t he fl ywh ool 01 \CI the
outGt oi lh e s1ator.
Check 1!IO ooodiMn ol "1 0 spar1< plug (Fig. 50-10)
and SGl lho gap 10 0.7nwn.
Cl>e<k !ho oond•M ol lhe spar1< plug cap(1'19-5(). 7),
look especially for arrt aad<s.
Each Yctow cable from the altofnalOf provides 7'1.V
ot outpv1 attached to 11'1e main electnca.I sy&te 1 n.
'"
0 1111 0111
IO_j •
Fog
$A
''•
5C

5 ALTERNATOR & IGNITION
ASSEMBLY OF ALTERNATOR/IGNITION
Th ofo ughly cle an lhe ins i cfe of lhe lfyvhleel cover
and the stator.
ln$lall the sta:orinto the
f!yvAiee l cover v1ith 1 he three
sc, c•t{S ( Fig .5C·1 ). u se a th (ead Jcd < liqui d, ! orq ue 8
Nm,
lns
1a ll Ule vJOodruff key (Fig. 5E·1) v1 ilh t he Ila! sur-
face of lhe keyinalignment \Viih the crankshaft co ne .
Ins ta ll the llY'vhee1 0010 Ille craokshafl cone and
'''Oodrv ff k ey .
Attach i he fl yv.·hee l holder (Fig. SF· I) inio one oi t he
slots in the ｦｬｾ ＢｨＧｬｬ･･ ｬ＠ and by usin9 1,vo or lhe llY'vheel
cov-er screv;s (Fig. SF · 2) .
Scre\v on Lile fly i.•1 hee1 nut, coun!er.c 1o ck v1 ise ( Fig.
5F- 3j, torque 50 Nm,
Insta ll Ill e llY'v hee-1 covei inclu di ng the slato r •N i th
lhe th re e sc re v;s.
AUach the •1,•ifiog of Il le stator 10 Il le 1nain \\•iring
harness and the ign ft ion coil.
IGNITION TIMING
Pot the engine in TDC (Fig. SG · 1).
R&move lhe i nspectiof"I oove r an d check the pos i tion
of the mac ks on t he f\)llo\'he el and the stator{Fig.5G·2}.
T
11e igni tion is prop e1ly se1if:
N oo -elecl ri:ca l starter n 1odels :
The left mark on the flyi.vhecl (Fi
g. . SH ·2) is aligned
•vith
Ａｩ ｾ･＠ ma rk on the ｳ ｬ ｡ｾ ｯｲ＠ ( Fi g. 5H·1) .
Electrical s
ta rter models:
The
ri ght ma1k on the Uy.vheal (Fig.5H·3) iSaligned
•11ith 1he ma rk on the staior (Fig.SH·1}.
If
the ignition needs to be adjusted. remove th e CO\'O f.
slightly undo the Lhree SC r e"o\'$ ol the stator (Fig. 5C-1)
and adjust the stato r.
Ti gl l !&O Il le S<: t e'A 'S (Ind CO\•ers .
ct· ®·'·
<P
.
Fi g.
51:
.,- Fig.
SF
Fig,
Fi g .
SH
11

12
6-A LUBRICATION SYSTEM
DISASSE MBLY OF OIL FIL TE RS
Dr ain t he engine o il by unscfe•1lio.g lhe oil dra in plug
(Fig. SA· 1}. Ti le Oi l screen (F ig . 6B·1) may ei 1 he1
f OllO\ \' the oil dra in plug or st ill be p os itioned \\'i ih in
the c< tu1kcasa v1hen the drain plug is <emoved .
U
nscre\'1 the t\vo sc re\•/S (Fig .6A·2) of the mieto fil let
cover (F ig. 6A-3).
Remove the o il screen (Fig. 68 · 1) by jusl pu ll ing it
oul of I ha cran k case .
Remove th e 1nk ro lillac c ove t by screv1 i ng in o.1e
f v16 screv1 inlo the center of the co...-er and use the
scre•11 as a pull er (F ig . 6B ·2 ).
U not accompanied by the fi lter cove t. pul l out 1J 1e
filter (Fig. 6C· 1).
Check the cond it io nsol the o·rings of the filler cov er
(Fig. 6C ·2) and ropl o. ce u1e1n if t hey sho\v any signs
of de letioralion.
Check the oil drainplug forany d amages, espe ci al ty
in regards to the lh re ad. Make the samo Cl leck
(ega rdi ng the ihread \V ithln lhe crankcase hall.
Check
tho s&a li ng '"asher ol t he drainpl ug { Fig .6f).2}
and the o4ri ngs on the o ll screeo { Fi g.60 44) for any
dan 1ages or deterioration.
Thorough
ly cl ean the o il scr een {Fig. 60
4
3j .
Replace ttle micro
fi lter {fig. 60 ·7).
Fig.
"'
F ig.
00
Fig.
"'
Fig ,
$D

6-A/8
LUBRICATION SYSTEM
ASSEM BL Y OF OIL FILTERS
Thoroughly cl ean the inner suriaces of ih e loca tic<i
of l he micfo fillet .... ,ithin ｵｾ･＠ c rankcase .
Clean the fil t er oover and the oil duct drilled through
the !lll er co ver (Fig. 6E · 1).
L ubrica te tho oil sea li ng \\•ithin t he gable of the fi!!er
(F ig. 6C · t) and the tv JOo-r ings oi theoo· .·e r(F ig .6 C·2) .
Gcn tfy insert the ｣ｯｾﾷ･ｲ＠ into the filter througll the oil
sea
1; ng ( F; g.6E· 2) .
Install the fil le r and co ... er in to the C r< l nkcase.
Screv1 on the tv1 0 sc ir e ·1 . •s, torque 5 Nm .
Thoroughly clean
the inne f su1faces of Ul a locati of i.
cl l he Oi l screen v1ithin the crankcase and the oil
drain pl ug .
Lubricate t he ll\' Oo ·r ings at the both ends of th e oil
screen and io sen the oil scree 1) into Ille oil chain
plug ( Fi g. 6F· 1).
Geni ly push the o il screen and drain pl ug into the-
cmnkcase until l he oil s.c r een fits i nt o 1he machined
pos iti on \v ithin the cm 11kca. se- . Sc < e·1" 01) these into
lhe bo:t om position, torque 12 N m.
Fil l !ho engine \\'ith Ihaadequate quaol il y of Ot l.
REED VALVE
T he reed va l ve (Fig. 6G ·2) is a sutije c1 of inspection
and cleaning ev-e ry 100 hou1s in orcle r to avoid any
disturbances.
0 1ain the
eng ine o il , remove the k ick.start l ever.
gearshiit I C.'VC t and 1he transmi ss issioo ｯｯ ｶｾ ｲ＠ ( see
Section 7A ).
Un screvttho tvJO SC ! C\•IS holding Ule (oocf vaJ\;esupJ):)r1
(Fig. GG ·1) and detach the support and t he reed
va l ve . Be co.rc ful ｮｯ ｾ＠ to dam age the scravtS 1hougi1
lhe y are fastened v1ith a threadlo ci< li qu id.
Inspect ther
ee-d val ve ( Fi g,6 H· 1) afKI th e rcedv atv e
suppo11(Fig.
6H ·2}forany ､｡ｭ｡ＹｾＧ［＠ 01 c!et e1iorati on.
C!ean t he p a. 1 1s and attach the mcnto the crankc ase.
using a ｴｨｲｾＮ｡､ ｬ ｯ｣ｫ＠ liquid O; l these1 e-.\
1$, I
Orque 5 N m.
R ef il the tr ansm i ss ion c ove ;. ki ck.star t and geafshllt
lever (see Sect ion 7A).
Fi ll the engine \vith the adcqua1e quantity of oil.
3
1
G©
2
Fig .
EG
Fig.
"'

6-C LUBRICATION SYSTEM
DI SASSEM BL Y OF OIL PUMP
Drain the eng i ne oi l.
Remo.,,.e the kid<.stan lc•.-er. Qarusl)ir1 le.,--er. transmission
co•1er and ti le dutch (see Section i A) .
Remove the ci rc li p (!=ig . 61-1) and the vtasher (Fig.
61·2) in 01der to re !ease the drive gear01 ti le oil pu mp
(Fig. 61·3). 8e careful not to lose the lock pin
underneath the drive gear (Fig.6J·1).
Re1nove lhe lock pin ( Fi g,6J·1}and the \vash e1 (Fig.
6J·2 ) fronl the oi l pump shat! ( Fi g. 6J· 3) .
unscr€'1\' the three scre-.\' S ｾ､ｩｮｧ＠ U1e oil pump cq.re r
and remove the
cove1. Becare iu l not to damage the
sete ' .vs though they are secured .... .ith a Lh re ad!ock
lf qu id ,
The cover is normally io ll O\ved by ll 'Wl oil puo1p shalt
and tile inner ro t or (see belo .. v).
Remo•1e the o il punlp Sllaft (Fi g. GK· 1) an-cf the inner
<otor (Fig. 6K-2) au ache<I to the sh o.f1 tiy a leek pin
( F; g. 6l·8) .
Remove theouter rotor (Fig, 6K·3).
C
hed< !he inoar an d ouler surfaces oj the o il pu mp
hOu$ing ior an}' damages Of dete1 10, a1 ion.
C
heck the coodllions of the inner and outer fO t OfS
for any damages or doteriofa!ion.
Check Iha oil pump shaft for any damages or
deter
ioca tion especially at ｴｨｾ＠ positi on of the oil
pump cover.
Fi g.
6J
'"' ·
GK
Fig,
GL

6-C LUBRICATION SYSTEM
ASSEMBL Y OF OIL PUMP
lnser! the outer rotor into the oil pump ho us ing, t he
ma t ks on the ro t or faci ng ou 1v1 a 1d s (F ig. Ｖｾ［Ｑ ﾷ Ｑ＠ ).
Posilion the inner ro1o r onto the o il pu mp shaft
1
1.' i th
t he lock pin (Fig. 6 L· 8), the matks on the inn.e t color
(Fig. 6fv 1· 2) and the lock ring spli ne on t he shaft (Fig.
Ｖｾ＾ＱＱＮｊ Ｉ＠ f acing ou1•11a rds.
Thoroughly clean the in
ner su rfa ce of the oil pump
cover and the sealing sur1ac0 a ro un d the oi l pump
r otors .
Add a thin la ye t of sil icone on 10 the sea li ng su rl ace
ar ound the ro1ors.
Pu ! on the Oi l pump cover onto lhe Shafi, the ma rk
on t he cover and the crankcase ha tf should align
(F ig.6N· 1) .
Sere-.,• on 1he th r ee scre ... •s, us i ng a th: eadlock li qu id.
torque 5 Nin .
Pu t one vtasher ( Fi g,6N·2) on 10 the shaft and th en
insert the loek pin (Fig. 6N·3) i nt o the shalt
Put the dri ... c gear(Fig.60 ·1}onto the shaft be careful
I C) align the spline on the ba dl.s- ide of the dri ve gear
'h' ith tho lock pin on Ill e shaft
Place one v1ashe <(Fig.6 0· 2) ontotheshaftandthen
loek tho
•1»ho !e dev tc e \\• i!h a ne• ... •eirciip (Fig. 60 ·3).
Install tile ciutch, the t
ransm is si on cover. the ki ck ·
s1 art and Ill e g&a rshift ｬ･ｯＮ ｾｲ＠ ( sea Section 7A).
Fill t he engine v 1ith ihe adequate quantity of oil.
-
-
-
---
Fig.
. ..
F ig..
6N
BO
15

••
7-A TRANSMISSION
DISASSEMBLY OF CLUTCH
Ortlln !ho engine oi.
Remove the k.idcsiatt teve1 and :he! gcarsh/1 lever .
UnSCf'C'>v t.hO six scrert.'S o7 the 11ansmillion CCNCf.
Ploas1 nole tha1 the l\vo sere-vs in tho 1root and the
r et11r (Fig. 7A· 1) are s!ightty longer l ha 1l lhe Olhor1ou<
OflOS (Fig 7•\·2).
Gontly f'OlllO\<e the cover •1, \1ho u1 rnaking an y ｾ Ｑｮ ｡Ｙ･ｳ＠
10 tho scal i1 19 s urla ces of tho covor and t he
ClC1nkor 1se ha l l.
ｾｉｬｬ･＠ ,.x wows (Fog. 78-1) '"""'ng 1ho d<M:ll
pressure plate aoss- ... 'ise in order 10 S)fevenl the
tricliOn· ano mating pb_tcs to &1ther ,am Of v1arp.
Remove these sue sae·."s inclvd ng 1c101ners and
spnngs.
Romove 1he pressure pla:e . be cafoful not 10 l ose
l he adjustmenl v1asher (Fig.No. 70·2) placod in
bo l•1 teon lhe bo(to rn ofoi ie pressure sloO\•o {Fig, 70-14}
and l ho push rod (Fig. 70· 1).
Romove l he clutch discs and the push rod.
Remove the cirolip (Fig,70· 7) on lhe main gear shah,
too1c>tig Ille dU1Ch h<Jb (F;g. 70-S) and lhoduech OU1ef
(Fig 70·5) .
Ptaoe a 1-U1able bolt (t. 110x:20 mm for 1ns1ance) in
1ht pushrOd Chan nel of the main gear shaft Anach
lho olulch hub puller (Fog .70-1, Ari No. 270005 ·0 1)
10 l hct clU1Ch h ub •1 Ji1h th ree ofthe p 1' 9\fic>usty remOVOd
sc1o v 1S.Scr e·1100 the coolerbolt ot tho puller 1zy11·arc1s
tho bott·hGild of ihe p:evi ou sJ y ptaoed bol t.
U se l he cfu:ch holder (F ;g. 7C-2 .Ari.No.270007·0 1)
\vhila s.cre ... 11ng on t he cen to ' !>OJI 01the pu ller un111
lho dutoh hub ｾ＠ te!e ased :rom ihe m.ol.n gear &haft .
Remove the washer
in bet,.,·een the dUlCh hub and
IlledlflCh OtJtcr. R..,..,... lhe dUICh CO- lncMfong
ll>o buShng and lhe wasllQr undemealll lho duleh
center.
Check ihc fnclion d is.c s (Fig, 70 · 11 } and ma ting
platos (Fi g. 70 - 12 ) in r egards lo any cJamages or
ske v1ness .Tile Ui c!i on d iscs h avo 10 be tepJaee cl it
tho v1ll ole package of f (1ctioo . ci nd m a1ing p10 1 es
ll\9asures bolo..v 19,6 mm. provided lhat lhe mating
plo.tos $110111 no signs of ske-.,·ness.
Check tho bushing (Fig. 7D-4) and the two'"ashcrs
(Fog .7().3) for M'f damages or de:enoroi.on.
Chock Ille lunct<>n and "'rt posJOtlle wear of Ille
boanng (Fog . 70· 13) and the pressuto """' (Fog.
70 ·14).
Checi< the splt0eson the main gear $h.&tt .
Chock the ma
in shaft bM11t19 (F 19 . 7E·1) fO( any
deterio ration O( da1na9es .
p
)..i, -
•
G©
•••
,.
...
7C
Fig,
70

7-A TRANSMISSION
ASSEMBLY
OF CLUTCH
Place one oi the t•110 vtashers (Fig. 7E ·2) and the
bushing (Fig. 7E-3) on I.he mai n sha.lt
\\fhire al igning tho clu:ch le• .. or. placed 01ltop of Ille
right $ide of the engine. ＹＰ ｾ＠ (the lever po inting
to •1 1ards the left side of the eng i ne) pu Sl l in the pu Sl l
rod (Fig. 8A · 4} i nto the main s hati .
Put th o clutch outer onto llle main sha fL
Put the seoond v1asher (Fig. 7F· t) onto the main
shaft and tho clutch outer.
V+/a rm the clutch hub (Fig. 7G · 1} in an oven or
lik ev 1iso to 200°C in ot<!e t to be able 10 slide ti le ll ub
onto lhe mainshaft.
P1,,1 oil t he ciu tc11 hub onto tile 1n ain shall using a
svi tabl:e s!eeve/socke1 on to p of the ce :nerof Ute hub
and a f na n et Secure 111 0k ict o(,s 1 ar1 mecha nism be lore
tapping onto ihe clutch hub in order to prc• 1en 1any
dama.ges to tile ki cks1ar 1 ｲｲ ｾ ･｣ｨ｡Ｚｮ ｩｳ ｭ Ｎ＠
Lc ci< the clutch hub onto the main sha h vlith a n c· N
ckclip (Fig. 7G ·2).
Place !he h ic li on discs .and lhe maiing plates into
the clutc h. slatting \Vith one 1n atin9 plat0 (l'= tg . 7G-3 },
IO llov1ed by one fr iction disc. then a maiing plate and
so on.The 8Lh ma 1i o9 plate beiog t he la$l one.
Add a da .b of grease onto the push rod top and place
the ctut c11 adju.st 1nen1 Sl l il n on lhis da b. Slide on t he
pres sure plate and be careful not to lose !he
adjustm en1 vtasher during U le p1o cedure.
Pu t the springs ( Fi g, 70-8) , the s-;:i :ing retainc:s (Fig.
70·1 0) and tho
sc r e·1o·s (Fig. 70-9) into lhe Slo ts ol
!he pressure plate.
Sere-." en th0 pr essu re f. )lale cros s•1 1ise ( Fi g. 76},
torque 10 Nm.
Tileclutch l eve r ontop of the engine shou kl engage
at 90 ., • ifn ot. change the ad ;uslment snim.
t..1ake su re thai both oi t he gu i de bushings arc in
S! taigh! a nd fixe d pos il ons . Pul a ne-." gasket onto
1he
crank case hali. Check the scali ngs In ! he
tr ansmission c ove r; ki ck.s t ar t shaft and gearshift
shaft,
fo r any daniages or v1earncss.
Sli de the cover ove r lhe shafts and the guide
bushings tovtards the crankcase llalf.Scte
·1o· oo the
Six $CrevtS, torque 10 Nm .
Attach t he gearShifl leve1 in p1e lered pos ilion. Slide
the
k.ic ks ta r1 lever onto the shaft in a position. the
lever facing out"'·ards, 1
us1 Sl igh Uy l ou ching the kick
starter stop
k.nob ( Fi g. 7G -'I). 1'-dd some threa.d l od<.
li qu id to 111 0 scre· 1,s of t he levers and tighten the
se<e'A'S using a iorque oi 10 Nn1.
Fi ll Il le 0n.9 1na vf.lh the adequate qoan:ity of oi l.
ll
• ..
_} I
Fi g.
"'
rig .
7G
17

18
7-8 TRANSMISSION
DISASSEMBLY OF GEARSHIFT MECHANISM
D ra in the eng i ne oil.
O isnlanue. the ki ¢.\S la rt l ever, the gearsh i fl lever. th&
tra ns mission cover an -d Ill e c rut ch ac co rding to
· Sect 10ll 7A.
Un sc re •11 thc bo ll ho lding the gearsh ift lo cation l eve r
(Fi 9. 71· 1) and remove the bol i, t.>i o \v-a .sher{Fig.71·2),
the lever {Fig. 71 -3), t he spr ing(71·4) and the sleeve
(Fig. 71·5) attached
to th e lever.
Unscre\v 1hc bolt holding ti le gear position star ( Fi g.
7 J· 1). Remove the bo l t. the '''asher (Fig. 7 J- 2) a t1 d
the positio1 l s1ar (F ig . 7J-3).
Oetach and remove the ha ir pin spting (Fig . 7J -4 )
including th o sleeve (Fig. 7J-5).
Ll
fl off lllegearshift shaftincl udi ng the g ea r selection
pl
ates ir om th e crankcase l );} l f.
C hock tile ge a rsh il1 k:x::al.ion l ever (F ig . 7K·3), posi t ion
ｳｾ｡ ｲ＠ (Fig. 7K·8) and the pt ns{Fig. 7K -..<J} fo r anjrdama·
ges0 1 deleriora!ion.
Ca r etul f> ; che ck th e surfaces ol lhe both the upper
geatSl)ift selection plate {Fig. 7K·
16 } and the fO'l\ •er
one ( Fig, 7K· 18). Grind oU any sharp edges and
check
!h at both plates are totally even and in
alignment
\vi th co.ch other.Ti le upper selection plaie
shoul
d. \V i!houl any fric tion . easity s fid' e ac,oss ll' )e
10\verse lecti on pl a1 e.
Each gear position as sho\vn in Fi gu re 7K, 0·6. The
iigure 0 representing
the position of the n eu tral. the
fi9ure 1
=
1st gearand so on. Please 1lotice tha t the
pin \vith a flat s urfa<' .e (Fig. 7l ·O) is !he posilioo of
the neolral p
osi1 io.- 1in the po si tion star (F ig. 7J · O).
Fig.
7J
7K
F!g.
7L

7-8
TRANSMISSION
A SS EMBLY OF GEA RSHIFTM E CHAN ISM
l ns :all !he g.aaf shi fl shaft including the selecti on
plates and the anachment sp ring.
Sl kl e the sleeve and the sp ri ng onto the sh ah and
install the ha ir pin spring intoits positio n. Plea. Se n ot e
that
the
ben 1 par1 ofth is spring sh ould be inthe posit ioo
as shmvn ( Fi g. 7\\'1 ·1).
lnsiall the gearposi tiQn slar (Fig. 7N·1 }. 1n s1a 1l thc
gAar "Sl lil! 1 cca1ion lever including sl eeve and spring
( Fi g- . 7 N· 2) by positioning the straight part of the
sp1in9 i nt o i ': s posi1 tc ,1 in tho et an kcase ha l f, sc re ·11
the bo lt in a fe-v tums,slide ;he ler ver ,e1ock\1 1i se , o ver
I ha position star and pl ace the \vheel of 1he l ev-e r
into its fi na l position in t he star. Please ob.S erve th at
Ille cha1nle re d edge of th e sleeve should be lacing
ouiv1a r ds and tov1ards the lever (Fi g. 7K· -1 ).
Che c .k that tile p lay :equal tonone. and the re sis tan ce
of the ha irpin spri ng (F ig.7N·3) is exactly Illesame
in bolh dCrections. Uan adjustment is ne
ede d, turn
the gearshift shait as s ho·11n (F ig. 7N ·A), use a plie(.
9
1ipp i n9 bo1n ends of the spri ng , adjust \he pat i of
the s pr ing needing an adjustment I O' .\•ardS Illeottlef.
lnstfill
the dutch. ! tans.m ission cove r, kicksi ar1 and
gearshift lever acco rd i ng to $S cii on 7A.
Fill
the engine v li ll l the ad eq uate quantiiy of oil.
Fig.
7N
70
••
I

20
7-C TRANSMISSION
DI
SASSEMBLY OF KI CKSTARTMECHANIS M
Drain ihe eng ine oil.
Dismantle thekickstan l evef, thQ gearshift l eve <. the
transmission cove r and the clutch accotd in9 to
Sac-l ion 7 A.
Remove lhe kickstart shaft {Fig.7P·1) incl ud iog t he
a tt ached k. icksta :t gear •11hee1 ( Fi g. 7P·2) by jus1
pulli
ng t he shaft ｳ ｾｲ ｡ｩｧｨｴ＠ out from the crankcase half.
ｾＱｯｳｴ＠ likely is also IJ le spring on the inside of Illa
gear v1 llee1accompanying the Sl laft an d the gear
•11hee 1vmen pulled out.
The function 01 Ute kickstan mechanism:
When the kickstart leve; is activated the kicks.t ar!
cngage1 n en1 key (Ftg .70 · 1) is engage d i nto the gear
ri ng of the k1c ksta11 gear v1hee l (Fig. 70 ·2 ) and Illus
the gear \vheel turning the intermediate gear •.vhee l
{ Fi g. 70 ·3).Thekick. sta rt mechanism is brought baek
to i ts hoine posi 1ion. \vhen released. by ! he spri ng
(Fig. 70 ·6). T he ongage-men t key is 'h'hen f Cs ti ng
to-."ards the engagement s!edgo {Fig. 70·8) \Vh i ch
is acting as bo1h a stop aoo a ､ ･｜ｾｃ･＠ <fe·activa1ing
the cnga9e1nent key fr om tho gear l'in9 of the ki c::k-
start gear \vhecl.
P1oducls equipped
wi lll a decompression device
activated by the
kickstart:
\"/hen
the ki ck start lever ts aclivated fr om the ｶ･ ｴｾＧ＠
to.o of the 01bi 1 .a 1 pa th the deoomptessioo de\'iCe (Fig.
7R · 4) li fts the doc omproo;sion fe.,.et (Fig. 7R·S) .\l'/heo
t
he ki cks tart mechani sm is brought b ac k the
c: hamtered edge of Ule cieoomp ression dovic& {Fig.
7R·7) puslles
the decompressio1l lev0 rbaek to \va rds
! he c rankcase ha lf tllu$ lelt i ng t he kicks1art
mechantsrn retvrn to its
ho : ne pos ition.
C
he ck t he buslli ng in the transmission cove r {Fig.
7S-1 ), the kickstart geat \vheel (Fig. 75·2). the
bearing (Fig. 7S- 3) and the l<id<s lart shalt (Fig. 7$- 4)
fo r any damagesor dctofioralioo. Especially t he sur·
fa ce and edge or1 l he d-eoompre ssion cse ... i ce { Fi g.
7R ·4, 7) and t he surlace of!hedecompression lcvet
{Fig.
7R ·5). Grind ott any tough sora!clles on t he
lever's front cc!9e and 1Jle surface on the boncm of
the IG '.'A r.
The engagomeo1
ｫｅｾＩＧ＠ ( Fi g.75·6) should bA replaced
ii it Sh O vlS si gn ificant •1.·ea' on t he sutface fa cing
tzy11a <c's the gear ring on t he ki ck sto.'1 gear \vheel.
Che-ck the engagonlent s1ea9e ( Fi g. 7 $· 8) for a.nt
deteriorati on 01damages.
［ ｾｾ＠
ＵＮ Ｑｾｾ＠
f f
Fig.
7P
F!g.
70
Fig.
7A
Fi g ,
7$