8. KICK STARTER/DRIVE PULLEY/
CLUTCH/DRIVEN PULLEY
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. KICK STARTER/DRIVE PULLEY/
CLUTCH/DRIVEN PULLEY
8. KICK STARTER/DRIVE PULLEY/
CLUTCH/DRIVEN PULLEY
SERVICE INFORMATION
GENERAL INSTRUCTIONS
• Avoid getting grease and oil on the drive belt and pulley faces.
Driven face spring free length
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
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.
8. 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 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.
8. KICK STARTER/DRIVE PULLEY/
CLUTCH/DRIVEN PULLEY
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