5-16 ENGINE RIGHT SIDE
Kickstarter
Kickshaft Removal
•
Remove:
Right Engine Cover (see Right Engine Cover Removal)
Clutch Housing
•
Pull the end of the kick spring [A] out of the hole in the
crankcase.
•
Remove the ratchet guide bolt [B] and ratchet guide screw
[C], take off the ratchet guide [D].
•
Remove the kickstarter assembly [E].
Kickshaft Installation
•
Torque the ratchet guide bolt and screw.
Torque - Ratchet Guide Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)
Ratchet Guide Screw: 5.2 N·m (0.53 kgf·m, 46
in·lb)
Kickstarter Assembly Disassembly/Assembly
•
The kickstarter assembly consists of the following parts.
•
Check the kickstarter assembly parts for damage. Any
damaged parts should be replaced with new ones.
A. Idle Gear
B. Circlip
C. Washer
D. Spring
E. Ratchet Gear
F. Kick Gear
G. Kick Shaft
H. Kick Spring
I. Spring Guide
•
Apply molybdenum disulfide grease to the inside of the
kick gear and ratchet gear.
•
When assembling the ratchet gear [A] onto the kick shaft
[B], align the notch [C] on the ratchet gear with the hole
[D] on the kick shaft.
•
Replace the circlips that were removed with new ones.
Special Tool - Outside Circlip Pliers: 57001-144
Idle Gear Removal
•
Remove:
Right Engine Cover (see Right Engine Cover Removal)
Clutch Housing (see Clutch Removal)
•
Remove the circlip [A] and pull off the idle gear [B].
Special Tool - Outside Circlip Pliers: 57001-144
Idle Gear Installation
•
Apply molybdenum disulfide grease to the inside of the
idle gear.
•
Replace the circlip with a new one.
Special Tool - Outside Circlip Pliers: 57001-144
