ENGINE REPAIR
 
28. In all cases, the maximum clearance is .008".  Replace the shift fork if it is greater.
NOTE: The shift drum should not wear as fast as the shift fork peg, so it is correct to replace the fork.  But the maximum width of any groove in shift drum at a gear position is .244". If the groove is wider, replace the drum.
29. Check the selector shaft and components for wear or damage.  Check the splines on the end of the shaft and check the shaft for straightness.  Check the tips of the selector pawl for wear or chipping.  Pull the pawl toward the left end of the shaft to be sure it is free.  Then release it to be sure the pawl spring is returning it properly.  Replace any defective or worn parts.
30. Check the selector shaft spring.  It should be tight against the pin pressed into the housing of the shaft.  Replace the spring if it is defective.
31. Check the two snap rings and the small lock ring on the shaft for wear or damage.  Be sure they're seated properly.
NOTE: Every snap ring has a square edge and a rounded edge (see FIGURE 29) because it is stamped out of a sheet of steel.  Always install a snap ring in its groove with the square edge facing in the direction the ring will be thrust under load.  Just imagine which way the snap ring would move if it came out of its groove.  Then install it with the square edge in that direction.
32. Check the splines on the end of the kick­starter shaft.  Check the teeth on the kick starter driving gear and spin the gear on the shaft to be sure it turns freely.

33. Check the matching teeth on the ratchet cam and the driving gear (see Figure 30).  Push the cam back and forth on the shaft. It should move about .4" toward the right end of the shaft and return by the spring pressure.

34. Remove the kick starter stop bolt in the rear of the case (see Figure 31).  It is threaded into the case and secured by a 14 mm lock nut in the hole outside the rear of the case.  Remove the lock nut, steel washer and fiber washer.  Then unscrew the stop bolt.
35. Check the stop bolt for wear or damage.  Replace if necessary.  Install the stop bolt with Loc-Tite on the threads.  The bottom of the head of the bolt should be .080" from the case shoulder.  Install the washers and lock nut and torque to 20 ft.-lbs.

36. Check the selector return spring anchor pin for wear or looseness in the case.  Always install it with Loc-Tite on the threads.
37. Carefully check all bearings and bushings for wear or damage.  Replace any doubtful part.

[previous page] [index] [next page]