Service manual

CHAPTER 5
ENGINE
ENGINE REMOVAL ……………………………………………………………………5-1
SIDE COVERS …………………………………………………………………5-1
COOLANT ………………………………………………………………………5-1
TRANSMISSION OIL …………………………………………………………5-1
EXHAUST PIPE ………………………………………………………………5-2
CARBURETOR …………………………………………………………………5-2
AUTOLUBE PUMP CABLE AND HOSE ……………………………………5-2
CLUTCH CABLE ………………………………………………………………5-3
Y.P.V.S. CABLES ………………………………………………………………5-3
RADIATOR HOSE………………………………………………………………5-4
LEADS …………………………………………………………………………5-4
DRIVE CHAIN …………………………………………………………………5-5
ENGINE DISASSEMBLY…………………………………………………………5-6
CYLINDER HEAD, CYLINDER AND PISTON ………………………………5-8
CLUTCH, PRIMARY DRIVE GEAR AND BALANCER GEAR ……………5-8
CLUTCH PUSH LEVER………………………………………………………5-11
SHIFT SAHFT AND STOPPER LEVER ……………………………………5-11
MAGNETO ROTOR …………………………………………………………5-12
REED VALVE …………………………………………………………………5-12
CRANKCASE (RIGHT) ………………………………………………………5-13
SHIFTER, TRANSMISSION AND BALANCER WEIGHT …………………5-14
CRANKSHFT …………………………………………………………………5-15
POWER VALVE ………………………………………………………………5-15
AUTOLUBE PUMP ASSEMBLY ……………………………………………5-16
INSPECTION AND REPAIR ……………………………………………………5-17
CYLINDER HEAD ……………………………………………………………5-17
CYLINDER AND PISTON ……………………………………………………5-18
PISTON RINGS ………………………………………………………………5-19
PISTON PIN AND BEARING ………………………………………………5-21
CLUTCH ………………………………………………………………………5-21
PRIMARY DRIVE ……………………………………………………………5-24
TRANSMISSION AND SHIFTER ……………………………………………5-25
SHIFT SHAFT AND STOPPER LEVER ……………………………………5-27
CRANKSHAFT ………………………………………………………………5-27
AUTOLUBE PUMP …………………………………………………………5-28
POWER VALVE ………………………………………………………………5-29
CRANKCASE …………………………………………………………………5-30
ENGINE ASSEMBLY AND ADJUSTMENTS ………………………………5-31
AUTOLUBE PUMP …………………………………………………………5-31
POWER VALVE ………………………………………………………………5-33
CRANKSHAFT AND BALANCER …………………………………………5-35
TRANSMISSION AND SHIFTER ……………………………………………5-36
CRANKCASE (RIGHT) ………………………………………………………5-39
REED VALVE …………………………………………………………………5-40
MAGNETO ROTOR …………………………………………………………5-41
STOPPER LEVER AND SHIFT SHAFT ……………………………………5-43
CLUTCH PUSH LEVER………………………………………………………5-46
BALANCER GEAR, PRIMARY DRIVE GEAR AND CLUTCH ……………5-47
PISTON CYLINDER AND CYLINDER HEAD………………………………5-52
REMOUNTING ENGINE ……………………………………………………5-56
ENG