5. Clutch assembly
a. Install the thrust plate onto the transmission main axle.
1. Thrust plate
b. Install the oil pump drive sprocket onto the main axle without the spacer collar and place the oil pump drive chain on its sprocket.
1. Oil pump drive sprocket
L. Lower Crankcase
1. Remove the dowel pin and "O-ring".
2. Remove the shift fork guide bar and shift forks. The shift forks are identified by numbers cast on their sides.
3. Remove the bolt securing the shift cam locating pin and remove the stopper plate and locating pin.
4. Remove the neutral switch.
IGNITION SYSTEM A. Circuit Diagram
Above circuit diagram shows only ignition circuit in wiring diagram.
B. Description
ELECTRIC STARTING SYSTEM
A. Circuit Diagram
Above circuit diagram shows starter circuit in wiring diagram.
B. Starter Motor
1. Removal (see CHAPTER 3. "ENGINE DISASSEMBLY")
2. Inspection and repair
C. Middle Gear Servicing
1. Disassembly
Refer to page 39 for disassembly.
2. Inspection
Refer to page 52 for inspection.
3. Gear lash check
NOTE:
The middle gear lash can be checked only when the gears are installed in the crankcase.
L. Transmission
1. Inspect each shift fork for signs of galling on gear contact surfaces. Check for bending. Make sure each fork slides freely on its guide bar.
2. Roll the guide bar across a surface place. If the bar is bent, replace.
PARTS ILLUSTRATIONS
I. Crankshaft
1. Crankshaft run-out
Support
the crankshaft at both ends on V-blocks. Measure the amount of
crankshaft run-out on the main bearing journals with a dial gauge while
rotating crankshaft.
Run-out limit: 0.040 mm (0.0016 in)
If run-out exceeds limit, replace crankshaft.
2. Inspection of bearings
11. Pistons and Cylinder a. Install the pistons on the rods. The arrow on the piston must point to the front of the engine.
NOTE:
Before installing the piston pin clips, cover the crankcase with a clean rag so you will not accidentally drop the circlip into the crankcase.
Always install new piston pin circlips.
INSPECTION AND REPAIR
A. Cylinder Head Cover
Place head cover on a surface plate. There should be no warpage. Correct by re-surfacing as follows:
Place #400 or #600 grit wet sandpaper on surface plate and re-surface head cover using a figure-eight sanding pattern. Rotate head cover several times to avoid removing too much material from one side.
B. Cylinder Head
