Service manual

CYLINDER AND PISTON..............................................................................4-34
REMOVING THE PISTON ......................................................................4-35
CHECKING THE CYLINDER AND PISTON ...........................................4-35
CHECKING THE PISTON RINGS...........................................................4-37
CHECKING THE PISTON PIN ................................................................4-38
INSTALLING THE PISTON .....................................................................4-40
INSTALLING THE CYLINDER ................................................................4-41
A.C. MAGNETO.............................................................................................4-42
REMOVING THE A.C. MAGNETO ROTOR............................................4-44
CHECKING THE STATOR COIL AND PICKUP COIL ............................4-44
CHECKING THE STARTER CLUTCH ....................................................4-45
CHECKING THE TORQUE LIMITER......................................................4-46
INSTALLING THE A.C. MAGNETO ROTOR ..........................................4-46
CLUTCH ........................................................................................................4-48
REMOVING THE CLUTCH .....................................................................4-50
CHECKING THE FRICTION PLATES.....................................................4-50
CHECKING THE CLUTCH PLATES .......................................................4-51
CHECKING THE CLUTCH SPRINGS.....................................................4-51
CHECKING THE CLUTCH HOUSING ....................................................4-51
CHECKING THE CLUTCH BOSS...........................................................4-52
CHECKING THE PRESSURE PLATE ....................................................4-52
CHECKING THE PUSH RODS ...............................................................4-52
CHECKING THE PUSH LEVER..............................................................4-52
CHECKING THE PRIMARY DRIVEN GEAR ..........................................4-52
INSTALLING THE CLUTCH....................................................................4-53
BALANCER ...................................................................................................4-55
REMOVING THE BALANCER DRIVE GEAR
AND BALANCER DRIVEN GEAR..........................................................4-56
CHECKING THE PRIMARY DRIVE GEAR, BALANCER DRIVE GEAR
AND BALANCER DRIVEN GEAR..........................................................4-56
CHECKING THE BALANCER .................................................................4-56
INSTALLING THE BALANCER DRIVE GEAR
AND BALANCER DRIVEN GEAR..........................................................4-57
OIL PUMP......................................................................................................4-58
CHECKING THE OIL PUMP ...................................................................4-60
SHIFT SHAFT................................................................................................4-61
CHECKING THE SHIFT SHAFT .............................................................4-63
CHECKING THE STOPPER LEVER ......................................................4-63
CHECKING THE SHIFT GUIDE AND SHIFT LEVER.............................4-63
CHECKING THE SHIFT DRUM SEGMENT ...........................................4-63
INSTALLING THE SHIFT LEVER ...........................................................4-63
INSTALLING THE SHIFT SHAFT ...........................................................4-64