7.
7. KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY MODEL SH10BA.SH10AA Torque: 5.0_ 6.0kg-m Torque: 3.5_ 4.5kg-m Torque: 3.5_ 4.
7. KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY SERVICE INFORMATION GENERAL INSTRUCTIONS • Avoid getting grease and oil on the drive belt and pulley faces. SPECIFICATIONS Item Drive pulley collar O.D. Movable drive face I.D. Weight roller O.D. Clutch outer I.D. Driven face spring free length Driven face O.D. Movable driven face I.D. Drive belt width TORQUE VALUES Drive face nut Clutch outer nut Clutch drive plate nut 3.5_ 3.5_ 5.
7. KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY Left Crankcase Cover KICK STARTER LEFT CRANKCAS E COVER REMOVAL Remove the drive belt cooling air tube connector circlip. Remove the nine left crankcase cover bolts, left crankcase cover and dowel pins. Inspect the left crankcase cover seal rubber for damage or deterioration. Bolt Kick Starter Spindle KICK STARTER SPINDLE REMOVAL Remove the kick lever from the kick starter spindle. Remove the circlip and washer from the kick starter spindle.
7. KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY Remove the kick starter spindle and return spring from the left crankcase cover. Remove the kick starter spindle bushing. Kick Starter Spindle Return Spring Spindle Return Spring KICK STARTER SPINDLE INSPECTION Inspect the kick starter spindle and gear for wear or damage. Inspect the return spring for weakness or damage. Inspect the kick starter spindle bushing for wear or damage.
7. KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY Inspect the kick starter spindle and driven gear forcing parts for wear or damage. Kick Starter Spindle Forcing Part Kick Starter Driven Gear Forcing Part KICK STARTER INSTALLATION Install the kick starter spindle bushing and return spring onto the left crankcase cover. * If the hooks of the return spring can not be installed properly, use a screw driver to press them into their locations respectively.
. KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY First install the washer and then the circlip onto the kick starter spindle. Install the kick lever. Washer Circlip Dowel Pins LEFT CRANKCASE COVER INSTALLATION First install the dowel pins and then the seal rubber. Seal Rubber Left Crankcase Cover Install the left crankcase cover and tighten the nine bolts diagonally. Connect the drive belt cooling air tube and install the circlip.
7. KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY DRIVE BELT Remove the left crankcase cover. INSPECTION Check the drive belt for cracks, separation or abnormal or excessive wear. Measure the drive belt width. Service Limit: SH10BA: 16.5mm replace if below SH10AA: 16.5mm replace if below * Use specified genuine parts for replacement. Clutch Outer Clutch Outer Nut REPLACEMENT Remove the nine left crankcase cover bolts and left crankcase cover.
7. KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY Clutch/Driven Pulley Remove the drive belt from the clutch/ driven pulley. Drive Belt DRIVE BELT INSTALLATION Turn the driven pulley clockwise and lift it up to expand the drive belt groove and then install a new drive belt. Drive Belt Set the drive belt on the drive pulley. Install the drive pulley face, starting ratchet and 12mm washer, then tighten the drive face nut. Torque: 3.5_ 4.
7. KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY DRIVE PULLEY Drive Pulley Face Starting Ratchet REMOVAL Hold the drive pulley with the holder and remove the 12mm drive face nut. Remove the starting ratchet, 12mm washer and drive pulley face. 12mm Drive Face Nut Movable Drive Face MOVABLE DRIVE FACE DISASSEMBLY Remove the movable drive face and drive pulley collar from the crankshaft. Drive Pulley Collar Ramp Plate Remove the ramp plate.
7. KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY Remove the weight rollers. Weight Roller MOVABLE DRIVE FACE INSPECTION Check each weight roller for wear or damage. Measure each roller O.D. Service Limit: SH10BA: 12.4mm replace if below SH10AA: 12.4mm replace if below DRIVE PULLEY INSTALLATION Install the drive pulley collar and movable drive face onto the crankshaft.
7. KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY Install the drive belt on the crankshaft. Install the drive face, starting ratchet and washer, then tighten the 12mm drive face nut. Torque: 3.5_ 4.0kg-m Drive Pulley Face * Keep grease or oil off the drive belt and drive pulley faces. Drive Face Nut Starting Ratchet STARTER PINION REMOVAL Remove the left crankcase cover. (7-3) Remove the drive pulley. (7-7) Remove the starter pinion.
7. KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY CLUTCH/DRIVEN PULLEY Clutch Outer 10mm Clutch Outer Nut CLUTCH/DRIVEN PULLEY REMOVAL Remove the drive pulley. (7-7) Hold the clutch outer with the universal holder and remove the 10mm clutch outer nut. Remove the clutch outer. Universal Holder Remove the clutch/driven pulley. Remove the drive belt from the clutch/driven pulley.
7. KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY Remove the seal collar. Seal Collar Driven Pulley Oil Seal Pull out the guide roller pins from the driven pulley and then remove the O-rings and oil seal from the driven pulley. O-rings CLUTCH/DRIVEN PULLEY INSPECTION Inspect the clutch outer for wear or damage. Measure the clutch outer I.D. Service Limit: SH10BA: 107.5mm replace if below SH10AA: 107.
7. KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY Check the clutch shoes for wear or damage. Measure the clutch lining thickness. Service Limit: 2.0mm replace if below Measure the driven face spring free length. Service Limit: SH10BA: 82.6mm replace if below SH10AA: 82.6mm replace if below Check the driven face assembly for wear or damage. Measure the driven face O.D. Service Limit: 33.94mm replace if below Check the movable driven face for wear or damage. Measure the movable driven face I.D.
7. KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY DRIVEN PULLEY FACE BEARING REPLACEMENT Check the needle bearings in the driven face and replace them if they have excessive play, damage or abnormal noise. Drive the inner bearing out of the driven pulley face. Inner Bearing Snap Ring Remove the snap ring and drive the outer bearing out of the driven face. Outer Bearing Bearing Outer Driver, 37x40mm Drive a new outer bearing into the driven face with the sealed end facing up.
7. KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY Bearing Driver Pilot Drive in a new needle bearing into the driven face with the mark facing up. Outer Driver, 24x26mm Driven Pulley Oil Seal CLUTCH/DRIVEN PULLEY AS SEMBLY First install the movable driven face onto the driven face. Then, install the guide roller pins, O-rings and a new oil seal. O-rings Guide Roller Pin Install the seal collar.
7. KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY Set the driven pulley, driven face spring and clutch assembly onto the clutch spring compressor. Compress the tool and install the 28mm drive plate nut. Tighten the 28mm nut to the specified torque. Torque: 5.0_ 6.0kg-m Clutch/Driven Pulley CLUTCH/DRIVEN PULLEY INSTALLATION Install the drive belt on the clutch/driven pulley and then install the clutch/driven pulley onto the drive shaft. Clutch Outer Install the clutch outer.