ENGINE DISASSEMBLY 

PRIMARY DRIVE COMPONENTS Removal
  1. Remove the 10 mm bolt holding the foot shift lever to the shaft.
  2. Remove the foot shift lever and the felt dust washer from the shaft.
  3. Remove the 11 mm bolt holding the kick­starter lever to the shaft.
  4. Remove the lever from the shaft.
  5. Remove the 10 screws that hold the primary case to the engine case.
  6. Use a large screwdriver to pry the primary case loose (see Figure 8). Put the screwdriver blade under the edge of the primary case inspection cover and over the end of the kick starter shaft. Pry until the case separates from the engine case and remove it.
  1. Remove the primary case gasket and the two locating guide pins.  The pins can be left in their holes if stuck there, but be careful not to damage them when handling the engine.
  2. Remove the spring washer and flat washer from the selector shaft.
  3. Remove the five cotter pins from their studs on the clutch assembly.
  4. Remove the five clutch spring nuts with a spanner screwdriver.
  5. Remove the clutch springs and spring cups.
NOTE: You can make your own screwdriver by cutting a notch
in the blade tip of a large screwdriver (see FIGURE 9).  The nuts can also be loosened with needle nosed pliers, but be careful not to damage the slots in the nuts.  Use the pliers to loosen the nuts until they're higher than flush with the ends of the studs. Then finish removing the nuts with a regular screwdriver.
  1. Remove all of the clutch plates.  The last plate is removed by putting two small screwdrivers under the edges and prying it out.
  2. The clutch has two push rods that run through the center of the transmission main shaft.  The rods are separated by a small ball bearing.
  3. Tilt the engine so the primary drive side is facing downward.



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