SERVICE INFORMATION -------------------------------------------- 8- 2 TROUBLESHOOTING ------------------------------------------------- 8- 2 LEFT CRANKCASE COVER------------------------------------------ 8- 3 DRIVE PULLEY -------------------------------------------------------- 8- 4 CLUTCH/DRIVEN PULLEY ------------------------------------------ 8- 8 KICK STARTER -------------------------------------------------------- 8-15
8-0
8. DRIVE AND DRIVEN PULLEYS/ KICK STARTER
SCHEMATIC DRAWING
8-1
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8. DRIVE AND DRIVEN PULLEYS/ KICK STARTER
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SERVICE INFORMATION GENERAL INSTRUCTIONS • The drive pulley, clutch and driven pulley can be serviced with the engine installed. • Avoid getting grease and oil on the drive belt and pulley faces. Remove any oil or grease from them to minimize the slipping of drive belt and drive pulley. SPECIFICATIONS Item Movable drive face bushing I.D. Drive face collar O.D. Drive belt width Clutch lining thickness Clutch outer I.D. Driven face spring free length Driven face O.D. Movable driven face I.D. Weight roller O.D. TORQUE VALUES Drive face nut Clutch outer nut Clutch drive plate nut
Clutch spring compressor Lock nut wrench, 39mm Kick starter spring remover
TROUBLESHOOTING Engine starts but motorcycle won‘t move • Worn drive belt • Broken ramp plate • Worn or damaged clutch lining • Broken driven face spring
Lack of power • Worn drive belt • Weak driven face spring • Worn weight roller • Faulty driven face
Engine stalls or motorcycle creeps • Broken clutch weight spring
8-2
8. DRIVE AND DRIVEN PULLEYS/
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KICK STARTER
Air Tube Band
LEFT CRANKCASE COVER REMOVAL Loosen the drive belt air tube band screw.
Bolts
Remove the left crankcase cover bolts and left crankcase cover. Remove the seal rubber and dowel pins.
Kick Lever
Left Crankcase Cover
Dowel Pins
INSTALLATION Install the dowel pins and the seal rubber.
Seal Rubber Left Crankcase Cover
Install the left crankcase cover.
＊ • Do not pull out the kick starter spindle. Press in the kick starter spindle when installing the left crankcase cover.
Install the cable clamp to the specified location. Install and tighten the left crankcase cover bolts.
Bolts
8-3
8. DRIVE AND DRIVEN PULLEYS/
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KICK STARTER
Install the drive belt air tube and tighten the tube band screw.
Tube Band Screw Universal Holder
DRIVE PULLEY REMOVAL Remove the left crankcase cover. Hold the drive pulley using an universal holder and remove the drive face nut and washer. Remove the drive pulley face. Special
Universal Holder Drive Pulley Face
Remove the drive belt from the movable drive face.
Movable Drive Face
Drive Belt
INSPECTION Check the drive belt for cracks, separation or abnormal or excessive wear. Measure the drive belt width. Service Limit: 17.5mm replace if below
＊•
Use specified genuine parts for replacement.
8-4
8. DRIVE AND DRIVEN PULLEYS/
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KICK STARTER
Remove the movable drive face assembly. Remove the drive pulley collar.
Drive Pulley Collar
Movable Drive Face Assembly
DISASSEMBLY Remove the ramp plate.
Ramp Plate
Remove the weight rollers.
Weight Roller
INSPECTION Check each weight roller for wear or damage. Measure each weight roller O.D. Service Limit: 16.00mm replace if below
8-5
8. DRIVE AND DRIVEN PULLEYS/ KICK STARTER
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Measure the movable drive face bushing assemblyy I.D. Service Limit: 27.20mm replace if over
Check the drive pulley collar for wear or damage. Measure the O.D. of the drive pulley collar sliding surface. Service Limit: 26.90mm replace if below
ASSEMBLY
Install the weight rollers into the movable drive face.
Weight Roller
8-6
8. DRIVE AND DRIVEN PULLEYS/
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KICK STARTER
Ramp Plate
Install the ramp plate.
Drive Pulley Collar
Insert the drive pulley collar into the movable drive face.
INSTALLATION Install the movable drive face onto the crankshaft.
Movable Drive Face Assembly
Lay the drive belt on the driven pulley. Set the drive belt on the drive pulley collar.
Drive Pulley Collar
Drive Belt
8-7
Driven Pulley
8. DRIVE AND DRIVEN PULLEYS/
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KICK STARTER
Install the drive pulley face, washer and drive face nut.
Drive Pulley Face
Washer
Hold the drive pulley with the universal holder and tighten the drive face nut. Torque: 49.0_ 58.5N-m
Drive Face Nut
Universal Holder
Special
Universal Holder
＊•
Do not get oil or grease on the drive belt or drive pulley faces. Drive Pulley
CLUTCH/DRIVEN PULLEY
Clutch Outer
Remove the left crankcase cover. (!8-3) Remove the drive pulley and drive belt. (!84) Hold the clutch outer with the universal holder and remove the clutch outer nut. Special
Universal Holder Remove the clutch outer. Universal Holder
INSPECTION Inspect the clutch outer for wear or damage. Measure the clutch outer I.D. Service Limit: 130.5mm replace if over
8-8
8. DRIVE AND DRIVEN PULLEYS/ KICK STARTER
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Check the clutch shoes for wear or damage. Measure the clutch lining thickness. Service Limit: 2.0mm replace if below
Clutch/Driven Pulley
CLUTCH/DRIVEN PULLEY DISASSEMBLY
Hold the clutch/driven pulley assembly with the clutch spring compressor.
＊•
Clutch Spring Compressor
Be sure to use a clutch spring compressor to avoid spring damage.
Special
Clutch Spring Compressor Set the tool in a vise and remove the clutch drive plate nut. Lock Nut Wrench Special
Lock Nut Wrench, 39mm Loosen the clutch spring compressor and disassemble the clutch/driven pulley assembly. Remove the seal collar.
8-9
8. DRIVE AND DRIVEN PULLEYS/ KICK STARTER
Pull out the guide roller pins and guide rollers. Remove the movable driven face from the driven face.
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Guide Roller Pin
Movable Driven Face
Remove the oil seal from the movable driven face.
Guide Roller
O-ring Oil Seal
INSPECTION Measure the driven face spring free length. Service Limit: 83.2mm 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
8-10
8. DRIVE AND DRIVEN PULLEYS/
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KICK STARTER
Check the movable driven face for wear or damage. Measure the movable driven face I.D. Service Limit: 34.06mm replace if over
DRIVEN PULLEY FACE BEARING REPLACEMENT Check the bearings for play and replace them if they have excessive play. Drive the inner needle bearing out of the driven pulley face.
＊•
Discard the removed bearing and replace with a new one. Inner Bearing
Remove the snap ring and drive the outer bearing out of the driven face.
＊•
Snap Ring
Discard the removed bearing and replace with a new one.
Apply grease to the outer bearing. Drive a new outer bearing into the driven face with the sealed end facing up. Special
Outer Bearing
Bearing Driver Seat the snap ring in its groove. Apply grease to the driven face bore areas.
＊ Pack all bearing cavities with 9_ grease.
8-11
9.5g
8. DRIVE AND DRIVEN PULLEYS/
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KICK STARTER
Press a new needle bearing into the driven face. Special
Bearing Driver
CLUTCH DISASSEMBLY Remove the circlips and retainer plate to disassemble the clutch.
＊
•
Circlips
Keep grease off the clutch linings.
Clutch Lining
Retainer Plate
8-12
8. DRIVE AND DRIVEN PULLEYS/ KICK STARTER
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CLUTCH ASS EMBLY
Install the damper rubbers on the drive plate pins. Install the clutch weights/shoes and clutch springs onto the drive plate. Install the retainer plate and secure with the circlips.
Circlips
Drive Plate Movable Driven Face
CLUTCH/DRIVEN PULLEY AS SEMBLY Clean the pulley faces and remove any grease from them. Apply grease to the O-rings and install them onto the moveable driven face.
8-13
8. DRIVE AND DRIVEN PULLEYS/
Bet & Win 125/150
KICK STARTER
Install the movable driven face onto the driven face. Apply grease to the guide rollers and guide roller pins and then install them into the holes of the driven face.
Guide Roller Pin
Guide Roller
Driven Face
Install the seal collar. Remove any excessive grease.
＊•
Movable Driven Face
Seal Collar
Be sure to clean the driven face off any grease.
Set the driven pulley assembly, driven face spring and clutch assembly onto the clutch spring compressor.
＊•
Align the flat surface of the driven face with the flat on the clutch drive plate. Compress the tool and install the drive plate nut. Set the tool in a vise and tighten the drive plate nut to the specified torque. Torque: 49.0_ 58.8N-m
＊•
Clutch Spring Compressor
Be sure to use a clutch spring compressor to avoid spring damage.
Lock Nut Wrench Special
Clutch Spring Compressor Outer Driver, 32x35mm INSTALLATION Install the clutch/driven pulley onto the drive shaft.
＊•
Keep grease off the drive shaft. Clutch/Driven Pulley
8-14
8. DRIVE AND DRIVEN PULLEYS/ KICK STARTER
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Install the clutch outer. Hold the clutch outer with the universal holder. Install and tighten the clutch outer nut. Torque: 49.0_ 58.8kg-m Special
Universal Holder Install the drive belt. (!8-7) Install the left crankcase cover. (!8-3) Kick Lever
KICK STARTER REMOVAL Remove the left crankcase cover. (!8-3) Remove the seal rubber and dowel pins. Remove the kick lever. Remove the circlip and washer from the kick starter spindle.
Kick Starter Spindle Starter Driven Gear
Gently turn the kick starter spindle to remove the starter driven gear together with the friction spring.
Friction Spring Kick Starter Spindle
Remove the kick starter spindle and return spring from the left crankcase cover. Remove the kick starter spindle bushing.
Return Spring
8-15
8. DRIVE AND DRIVEN PULLEYS/
Bet & Win 125/150
KICK STARTER
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 bushings for wear or damage.
Spindle
Return Spring
Plastic Bushing
Spindle Bushing
Friction Spring
Inspect the starter driven gear for wear or damage. Inspect the friction spring for wear or damage.
Starter Driven Gear Kick Starter Spindle Forcing Part
Inspect the kick starter spindle and starter driven gear forcing parts for wear or damage.
INSTALLATION Install the kick starter spindle bushings and return spring onto the left crankcase cover.
Starter Driven Gear Shaft Forcing Part Starting Ratchet
＊ When installing the return spring, use a screw driver to press the inward and outward return spring hooks into their original positions respectively.
Install the starter driven gear and friction spring as the figure shown.
Friction Spring
Kick Starter Spindle
8-16
8. DRIVE AND DRIVEN PULLEYS/ KICK STARTER
Bet & Win 125/150
Install the kick lever. Install the left crankcase cover and tighten the cover bolts diagonally. Connect the drive belt air tube and tighten the band screw.
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