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  3. ENDURO FE 501

HUSABERG ENDURO FE 501, Enduro II FE 501 S User manual

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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
EN DU RO MOTOCROSS ELDURO DESERT
Liquid
coo&ed
. 4·stroke single
cy11nde1,
SOHC-4 \'8.f\'CS
----
400-mod:els
: 399cc I Bore 92.0 mm x
S1ro
ke
G0.2
mm
501
·models;
501
cc I Bo
re
95.0 mi
nx
Stroke
Ｗ
ＰＬＷｾ
ｭ ｭ＠
600·mod
els;
595
cc I Soro 95,0 mi
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, 1 o 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
t Ratios 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 • 2.61 s 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.ro H
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)
501/6-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
OR2 70
_:...:......
__
_:_
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 5 1
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'--
DU AL SPORT
FS600
E
K35
K 5 1
K
51
K
51
K51
K
51
KS1
K
51
K 5 1
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
I 1i;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
1 O N m
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. please take 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 if your 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
force@husaberg.se
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
SUBJECT I 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
•
••
Oean wl'IOl'l(Mlf
lhO
019
1
\0
has
been \\tish£11.1 •
••
• l(B): [spocia1y noode
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 11 scr
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 i a p h
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
the ahli
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 cover and c
hec.l<
tile o-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-
1 t
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 thus causi
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
!he p!
ug
and
the
ｾｩ
ｮｧ＠
of t
he
d
lam
ber
for
a;iy d
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
'e set
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 or deteliot
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 th0 diaphragm
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 surfaces ol t
he
1•
1;o reeds (
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 !he Stator
1s
going
lO
be
drsmounted disconnocl the
•11.-i
ri
ng
hainess of lhe 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.
U l
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 168 Ohm 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
tho o
il
se
al
of lhc
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:or into 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 key in alignment
\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 T IMING
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
se1 if:
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) iS aligned
•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
ns ol
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 drain plug for any 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
drain pl
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 ,
$D
6-A/8
LUBRICATION SYSTEM
ASSEM
BL
Y
OF
OIL FILTERS
Thoroughly cl
ean
the
inner suriaces
of
ih
e loca
tic<i
of l
he
micfo fillet
....
,ithin
ｵｾ･＠
c
rankcase
.
Clean
the
fil
t
er
oover
and
the oil duct drilled through
the
!lll
er
co
ver (Fig.
6E
· 1).
L
ubrica
te
tho
oil sea
li
ng
\\•ithin
t
he
gable of the
fi!!er
(F
ig.
6C
·
t)
and the
tv
JOo-r
ings
oi
theoo·
.·e
r (F
ig
.6
C·2)
.
Gcn
tfy
insert
the
｣ｯｾﾷ･ｲ＠
into the filter througll the oil
sea
1;
ng
(
F;
g. 6E·
2)
.
Install the fil
le
r
and
co
...
er
in
to
the
C
r<
l
nkcase.
Screv1
on
the
tv1
0
sc
ir
e
·1
.
•s,
torque 5
Nm
.
Thoroughly clean
the
inne
f
su1faces
of
Ul
a locati
of
i.
cl l
he
Oi
l screen v1ithin the crankcase
and
the oil
drain pl
ug
.
Lubricate t
he
ll\'
O o
·r
ings
at
the
both
ends
of
th
e oil
screen and io
sen
the oil
scree
1) into Ille oil
chain
plug (
Fi
g. 6F· 1).
Geni
ly
push the o
il
screen and drain pl
ug
into
the-
cmnkcase until l
he
oil
s.c
r
een
fits i
nt
o
1he
machined
pos
iti
on
\v
ithin
the
cm
11kca.
se-
.
Sc
<
e·1"
01) these into
lhe bo:t
om
position, torque
12
N
m.
Fil
l !ho engine \\'ith Iha adequate quaol
il
y of
Ot
l.
REED VALVE
T
he
reed
va
l
ve
(Fig.
6G
·2) is a sutije
c1
of inspection
and cleaning
ev-e
ry
100
hou1s in
orcle
r to
avoid
any
disturbances.
0 1ain the
eng
ine o
il
, remove the k
ick.start
l
ever.
gearshiit I
C.'VC
t and
1he
transmi
ss
issioo
ｯｯ
ｶｾ
ｲ＠
(
see
Section
7A
).
Un
screvttho
tvJO
SC
!
C\•IS
holding
Ule
(oocf
vaJ\;esupJ):)r1
(Fig.
GG
· 1) and detach
the
support
and
t
he
reed
va
l
ve
. Be
co.rc
ful
ｮｯ
ｾ＠
to dam
age
the
scravtS
1hougi1
lhe
y are
fastened
v1ith
a threadlo
ci<
li
qu
id.
Inspect the r
ee-d
val
ve (
Fi
g, 6
H·
1)
afKI
th
e rcedv
atv
e
suppo11 (Fig.
6H
·2} for any
､｡ｭ｡ＹｾＧ［＠
01
c!et
e1iorati
on.
C!ean t
he
p
a.
1
1s
and attach
the
mcnto the crankc
ase.
using
a
ｴｨｲｾＮ｡､
ｬ
ｯ｣ｫ＠
liquid
O;
l the se1
e-.\
1$, 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 gear 01
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.
Be care
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
the outer 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)
onto the shaft and then
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 7 A).
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. 7 A·
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
of oi
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 lho duech
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 of the p
1'
9\fic>usty
remOVOd
sc1o
v
1S.Scr
e·1100
the
cooler bolt 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
01 the
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
Ille dlflCh
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 $ide of the engine.
ＹＰ
ｾ＠
(the lever
po
inting
to
•1
1ards
the
left side of the
eng
i
ne)
pu
Sl
l in
the
pu
Sl
l
rod (Fig.
8A
·
4}
i
nto
the
main
s
hati
.
Put
th
o clutch outer onto llle main sha
fL
Put the seoond
v1asher
(Fig. 7F· t) onto the main
shaft and tho clutch outer.
V+/a
rm the clutch hub (Fig.
7G
·
1}
in
an
oven
or
lik
ev
1iso to 200°C in
ot<!e
t to be able
10
slide
ti
le
ll ub
onto lhe main shaft.
P1,,1
oil t
he
ciu
tc11
hub
onto tile
1n
ain shall
using
a
svi
tabl:e
s!eeve/socke1
on
to
p of
the
ce
:ner of
Ute
hub
and
a f
na
n
et
Secure
111
0 k
ict
o(,s
1
ar1
mecha
nism
be
lore
tapping onto
ihe
clutch hub in order
to
prc•
1en
1 any
dama.ges
to tile ki
cks1ar
1
ｲｲ
ｾ
･｣ｨ｡Ｚｮ
ｩｳ
ｭ
Ｎ＠
Lc
ci<
the clutch hub onto the main
sha
h vlith a n
c·
N
ckclip (Fig.
7G
·2).
Place
!he
h
ic
li
on
discs
.and
lhe maiing plates into
the
clutc
h.
slatting
\Vith
one
1n
atin9
plat0
(l'=
tg
.
7G-3
},
IO
llov1ed
by
one
fr
iction disc. then a maiing plate and
so
on. The
8Lh
ma
1i
o9
plate
beiog
t
he
la$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 N m.
Tile clutch l
eve
r ontop of the engine shou
kl
engage
at
90
.,
• if n
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
7-8
TRANSMISSION
A
SS
EMBLY OF
GEA
RSHIFT M 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 into its positio
n.
Plea.
Se
n
ot
e
that
the
ben
1
par1
of th
is
spring
sh
ould
be
in the
posit
ioo
as shmvn (
Fi
g.
7\\'1
·1).
lnsiall
the
gear posi
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 to none. and the
re
sis
tan
ce
of
the
ha
ir pin spri
ng
(F
ig. 7N·3) is exactly Ille same
in bolh dCrections. U an 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
Ille ottlef.
lnstfill
the
dutch. !
tans.m
ission
cove
r, kicksi
ar1
and
gearshift lever acco
rd
i
ng
to
$S
ci i
on
7 A.
Fill
the
engine v
li
ll
l the ad
eq
uate quantiiy of oil.
Fig.
7N
70
••
I
20
7-C TRANSMISSION
DI
SASSEMBLY
OF
KI
CKSTARTMECHANIS
M
Drain
ihe
eng
ine
oil.
Dismantle the kickstan l
evef,
thQ
gearshift l
eve
<.
the
transmission
cove
r
and
the clutch
accotd
in9 to
Sac-l
ion 7
A.
Remove lhe kickstart shaft {Fig. 7P· 1) incl
ud
iog t
he
a
tt
ached
k.
icksta
:t
gear
•11hee1
(
Fi
g. 7P·2) by jus1
pulli
ng
t
he
shaft
ｳ
ｾｲ
｡ｩｧｨｴ＠
out from
the
crankcase half.
ｾＱｯｳｴ＠
likely is also
IJ
le spring
on
the inside
of
Illa
gear
v1
llee1 accompanying
the
Sl
laft
an
d
the
gear
•11hee
1 vmen pulled out.
The function
01
Ute kickstan mechanism:
When the kickstart leve;
is
activated the
kicks.t
ar!
cngage1
n
en1
key
(Ftg
. 70 ·
1)
is
engage
d i
nto
the
gear
ri
ng
of
the
k1c
ksta11
gear
v1hee
l (Fig. 70
·2
)
and
Illus
the gear \vheel turning the intermediate gear
•.vhee
l
{
Fi
g.
70
·3). The kick.
sta
rt mechanism is brought
baek
to i
ts
hoine
posi
1ion. \vhen released.
by
!
he
spri
ng
(Fig.
70
·6). T
he
ongage-men
t key is
'h'hen
f
Cs
ti
ng
to-."ards
the
engagement s!edgo {Fig.
70·8)
\Vh
i
ch
is
acting as
bo1h
a stop
aoo
a
､
･｜ｾｃ･＠
<fe·activa1ing
the
cnga9e1nent key
fr
om
tho
gear
l'in9
of the
ki
c::k-
start gear \vhecl.
P1oducls equipped
wi
lll
a decompression device
activated by the
kickstart:
\"/hen
the
ki
ck
start lever ts aclivated fr
om
the
ｶ･
ｴｾＧ＠
to.o
of the
01bi
1
.a
1
pa
th
the
deoomptessioo de\'iCe (Fig.
7R
·
4)
li
fts
the
doc
omproo;sion
fe.,.et (Fig.
7R·S)
. \l'/heo
t
he
ki
cks
tart mechani
sm
is brought b
ac
k the
c:
hamtered edge of Ule
cieoomp
ression dovic& {Fig.
7R· 7) puslles
the
decompressio1l
lev0
rbaek to
\va
rds
!
he
c rankcase ha
lf
tllu$
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 kicks tart geat \vheel (Fig. 75·2). the
bearing (Fig.
7S-
3) and
the
l<id<s
lart shalt (Fig. 7$-
4)
fo
r any damages or 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 !he decompression 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
$·
8) for
a.nt
deteriorati
on
01 damages.
［
ｾｾ＠
ＵＮ
Ｑｾｾ＠
f f
Fig.
7P
F!g.
70
Fig.
7A
Fi
g ,
7$
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