Kymco MO P50 Service Manual - chap 08 (trasmissione)

8. KICK STARTER/DRIVE PULLEY/

CLUTCH/DRIVEN PULLEY

8-0

8

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KICK STARTER/DRIVE PULLEY/

CLUTCH/DRIVEN PULLEY

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SERVICE INFORMATION........................................................ 8- 3

TROUBLESHOOTING.............................................................. 8- 3

KICK STARTER....................................................................... 8- 4

DRIVE BELT ........................................................................... 8- 8

DRIVE PULLEY....................................................................... 8-10

STARTER ONE-WAY CLUTCH DRIVE GEAR ......................... 8-12

CLUTCH/DRIVEN PULLEY ..................................................... 8-15

8

8. KICK STARTER/DRIVE PULLEY/

CLUTCH/DRIVEN PULLEY

8-1

MODEL BA10AB.AC.

Torque:

3.5_ 4.5kg-m

Torque:

5.0_ 6.0kg-m

Torque:

3.5_ 4.0kg-m

8. KICK STARTER/DRIVE PULLEY/

CLUTCH/DRIVEN PULLEY

8-2

SERVICE INFORMATION

GENERAL INSTRUCTIONS

• Avoid getting grease and oil on the drive belt and pulley faces.

SPECIFICATIONS

BA10AB.AC.50

Item

Standard (mm)

Service Limit (mm)

Drive pulley collar O.D.

20.01_ 20.025

24.24

Movable drive face I.D.

20.035_ 20.085

19.97

Weight roller O.D.

13.0

12.4

Clutch outer I.D.

107_ 107.2

107.5

Driven face spring free length

87.9

82.6

Driven face O.D.

33.965_ 33.985

33.94

Movable driven face I.D.

34.0_ 34.25

34.06

Drive belt width

18

17

TORQUE VALUES

Drive face nut 3.5_ 4.0kg-m
Clutch outer nut 3.5_ 4.5kg-m
Clutch drive plate nut 5.0_ 6.0kg-m

SPECIAL TOOLS

Lock nut wrench, 39mm Universal holder
Clutch spring compressor Lock nut socket wrench, 32mm
Bearing outer driver 37x40mm Bearing driver pilot, 17mm
One-way clutch puller Outer driver, 24x26mm

TROUBLESHOOTING

Poor performance at high speed or

Engine starts but motorcycle won‘t move lack of power

• Worn drive belt • Worn drive belt

• Broken ramp plate • Weak driven face spring

• Worn or damaged clutch lining • Worn weight roller

• Faulty driven face

Engine stalls or motorcycle creeps

• Broken clutch weight spring

8. KICK STARTER/DRIVE PULLEY/

CLUTCH/DRIVEN PULLEY

8-3

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.

KICK STARTER SPINDLE REMOVAL

Remove the kick lever from the kick starter
spindle.
Remove the circlip and washer from the
kick starter spindle.

Slightly rotate the kick starter spindle to
remove the kick starter driven gear together
with the friction spring.

Left Crankcase Cover

Bolt

Friction Spring

Kick Starter Driven Gear

Kick Starter Spindle

Washer

Circlip

8. KICK STARTER/DRIVE PULLEY/

CLUTCH/DRIVEN PULLEY

8-4

Remove the kick starter spindle and return
spring from the left crankcase cover.
Remove the kick starter spindle bushing.

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.

Check the kick starter driven gear for wear
or damage.
Check the friction spring for wear or
damage.

Kick Starter Spindle

Return Spring

Spindle

Plastic Bushing

Spindle Bushing

Return Spring

Friction Spring

Kick Starter Driven Gear

8. KICK STARTER/DRIVE PULLEY/

CLUTCH/DRIVEN PULLEY

8-5

Inspect the kick starter spindle and driven
gear forcing parts for wear or damage.

KICK STARTER INSTALLATION

Install the kick starter spindle bushing and
return spring onto the left crankcase cover.

Properly install the kick starter driven gear
and friction spring as the figure shown.

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 Spindle Forcing Part

Kick Starter Driven Gear Forcing Part

Friction Spring

Kick Starter Spindle

Friction Spring

Kick Starter Driven Gear

8. KICK STARTER/DRIVE PULLEY/

CLUTCH/DRIVEN PULLEY

8-6

First install the washer and then the circlip
onto the kick starter spindle.
Install the kick lever.

LEFT CRANKCASE COVER
INSTALLATION

First install the dowel pins and then the seal
rubber.

Install the left crankcase cover and tighten
the ten bolts diagonally.
Connect the drive belt cooling air tube and
install the circlip.

Left Crankcase Cover

Rear Brake Cable Clamp

Seal Rubber

Dowel Pins

Washer

Circlip

For drum brake, note the location of the
brake cable clamp and install the rear
brake cable in place with the clamp.

＊

8. KICK STARTER/DRIVE PULLEY/

CLUTCH/DRIVEN PULLEY

8-7

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:
BA10AB.AC.50: 16.5mm replace if below

REPLACEMENT

Remove the ten left crankcase cover bolts
and left crankcase cover. (!8-4)
Hold the clutch outer with the universal
holder and remove the 10mm clutch outer
nut and clutch outer.

Hold the drive pulley with the holder and
remove the 12mm drive face nut.
Remove the starting ratchet.
Remove the drive pulley face.

Use specified genuine parts for replace­ment.

＊

Clutch Outer

Drive Face Nut

Drive Face

Universal Holder

Clutch Outer Nut

Ratchet

8. KICK STARTER/DRIVE PULLEY/

CLUTCH/DRIVEN PULLEY

8-8

Remove the drive belt from the clutch/
driven pulley.

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.

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_ 4.0kg-m

Clutch/Driven Pulley

Drive Belt

Drive Belt

Drive Pulley Face

12mm Washer

Drive Belt

Starting Ratchet

Drive Face Nut

When installing the drive face nut, make
sure that the tooth spaces of the drive
pulley face and starting ratchet align
with the teeth of the crankshaft.

＊

8. KICK STARTER/DRIVE PULLEY/

CLUTCH/DRIVEN PULLEY

8-9

DRIVE PULLEY

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.

MOVABLE DRIVE FACE
DISASSEMBLY

Remove the movable drive face and drive
pulley collar from the crankshaft.

Remove the ramp plate.

Movable Drive Face

Ramp Plate

Drive Pulley Collar

12mm Drive Face Nut

Starting Ratchet

Drive Pulley Face

8. KICK STARTER/DRIVE PULLEY/

CLUTCH/DRIVEN PULLEY

8-10

Remove the weight rollers.

MOVABLE DRIVE FACE INSPECTION

Check each weight roller for wear or
damage.
Measure each roller O.D.

Service Limit:
BA10AB.AC.50: 12.4mm replace if below

DRIVE PULLEY INSTALLATION

Install the drive pulley collar and movable
drive face onto the crankshaft.

Weight Roller

Movable Drive Face

Drive Pulley Collar

8. KICK STARTER/DRIVE PULLEY/

CLUTCH/DRIVEN PULLEY

8-11

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

STARTER PINION

REMOVAL

Remove the left crankcase cover. (!8-4)
Remove the drive pulley. (!8-8)
Remove the starter pinion.

INSPECTION

Inspect the starter pinion seat for wear.
Inspect the starter pinion for smooth
operation.
Inspect the starter pinion shaft forcing
parts for wear and damage.

INSTALLATION

Apply a small amount of grease to the
starter pinion teeth.
Install the starter pinion in the reverse order
of removal.

Keep grease or oil off the drive belt and
drive pulley faces.

＊

Drive Face Nut

Starting Ratchet

Drive Pulley Face

Starter Pinion

Shaft Forcing Parts

Starter Pinion

8. KICK STARTER/DRIVE PULLEY/

CLUTCH/DRIVEN PULLEY

8-12

CLUTCH/DRIVEN PULLEY

CLUTCH/DRIVEN PULLEY REMOVAL

Remove the drive pulley. (!8-8)
Hold the clutch outer with the universal
holder and remove the 10mm clutch outer
nut.
Remove the clutch outer.

Remove the clutch/driven pulley.
Remove the drive belt from the
clutch/driven pulley.

CLUTCH/DRIVEN PULLEY DIS­ASSEMBLY

Compress the clutch/driven pulley spring
with the clutch spring compressor and
remove the 28mm drive plate nut.
Remove the driven face spring.

Clutch/Driven Pulley

Universal Holder

Clutch Outer

10mm Clutch Outer Nut

Clutch Spring Compressor

Lock Nut Wrench, 39mm

8. KICK STARTER/DRIVE PULLEY/

CLUTCH/DRIVEN PULLEY

8-13

Remove the seal collar.

Pull out the guide roller pins from the
driven pulley and then remove the O-rings
and oil seal from the driven pulley.

CLUTCH/DRIVEN PULLEY
INSPECTION

Inspect the clutch outer for wear or damage.
Measure the clutch outer I.D.

Service Limit:
BA10AB.AC.50: 107.5mm replace if below

Seal Collar

Oil Seal

O-rings

Guide Roller Pin

Driven Pulley

8. KICK STARTER/DRIVE PULLEY/

CLUTCH/DRIVEN PULLEY

8-14

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:
BA10AB.AC.50: 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.

Service Limit: 34.06mm replace if below
Check the guide roller pins for stepped

wear.

8. KICK STARTER/DRIVE PULLEY/

CLUTCH/DRIVEN PULLEY

8-15

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.

Remove the snap ring and drive the outer
bearing out of the driven face.

Drive a new outer bearing into the driven
face with the sealed end facing up.
Seat the snap ring in its groove.

Snap Ring

Bearing Outer Driver, 37x40mm

Inner Bearing

Outer Bearing

Pack all bearing cavities with

5.0_ 5.6g grease.
Specified grease: 230℃ Heat-resistant

grease

＊

8. KICK STARTER/DRIVE PULLEY/

CLUTCH/DRIVEN PULLEY

8-16

Drive in a new needle bearing into the
driven face with the mark facing up.

CLUTCH/DRIVEN PULLEY ASSEMBLY

First install the movable driven face onto
the driven face. Then, install the guide
roller pins, O-rings and a new oil seal.

Install the seal collar.

Seal Collar

Oil Seal

O-rings

Guide Roller Pin

Driven Pulley

Bearing Driver Pilot

Outer Driver, 24x26mm

8. KICK STARTER/DRIVE PULLEY/

CLUTCH/DRIVEN PULLEY

8-17

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
INSTALLATION

Install the drive belt on the clutch/driven
pulley and then install the clutch/driven
pulley onto the drive shaft.

Install the clutch outer.
Hold the clutch outer with the universal
holder.
Install and tighten the 10mm clutch outer
nut.

Torque: 3.5_ 4.5kg-m
Install the left crankcase cover. (!8-7)

Universal Holder

Clutch Outer

Clutch/Driven Pulley