Suggested Operation - assemble Tool
Description
Sequence
Click for photos; use 'back' button to return
Step 1 (image
1) (after following operation
for sealing case halves) carefully
insert crank assembly into a case half
- light oil can be used for ease of fit
place other case half over crank assembly
tap case(s) together to form a square seal at the
interface
2 install primary & secondary shaft as one unit
- be sure both standard
lower shifter forks are aligned correctly with the
matching gears the respective gears -
upper fork can be installed when both shafts are
secure in case -
replace pivot shafts for shifter forks making sure
the fork(s)
pivot freely on shaft(s)
loose assemble (17) crankcase screws
install ignition & clutch side seals
Step 2. Tool, size: standard 6mm hex wrench.
Install
primary & secondary
shaft as one unit - be sure both
lower shifter forks are aligned correctly the respective
gears -
upper fork can be installed when both shafts are
secure in case -
replace pivot shafts for shifter forks making sure
the fork(s)
pivot freely on shaft(s)
loose assemble (17) crankcase screws
install ignition & clutch side seals
Step 3 (image
3) Tool, size: standard 6mm
hex wrench.
replace cylinder - install new gasket
if required lightly lube & start
cyl over piston by tilting slightly forward
to close ring gap allowing cyl to slip
over piston - loose assemble (4) cylinder
nuts item - rotate crank asm to center & tighten
nuts at this point loosen all cylinder
nuts, now tighten all case screws (this
allows case halves & cylinder
to mount flush) re-tighten
cylinder nuts
Step 4 (image4)
Tool, size: standard
5mm hex wrench.
install stator plate (standard 5mm
hex wrench)
loose assemble (3) stator plate screws
Step 5 (image 5)
Tools, size: standard/ spanner & 17mm,
then special 17mm socket
install
PVL rotor install key, rotor & rotor
nut using spanner standard/ spanner & 17mm
to hold crankshaft while tightening special 17mm
socket
Step 6 (image 6)
Tool, size: standard snap ring pliers
install drive gear on crank spline
ensuring that gear is in proper position
install 20mm snap ring standard snap ring pliers
7 (image 7) Tool,
size: standard
5mm hex wrench
install
clutch cover with gasket install (10) clutch cover
screws
8 (image 8) Tools,
size: standard
spanner, special
20mm socket
install
thrust washer on primary shaft install clutch hub
(standard/ spanner) install clutch hub spacer (special
20mm socket)
install clutch hub nut
9 (image 9) Tool,
size: standard/ standard 13mm socket
install clutch plates
- start with friction then alternate steel/friction
(standard 13mm socket) install (5) pressure plate
springs & nuts
time engine to mfg specs
! common sense is the best test for torque especially
when fastener
is steel and part is aluminum
suggested torque values for:
5mm - 6 ft-lb 8 nm aluminum
6mm - 12 ft-lb 7 nm aluminum
8mm - 14 ft-lb 18 nm aluminum
12mm - 60 ft-lb 80 nm steel
14mm - 100 ft-lb 135.5 nm steel
See also:
