Honda FQ650 Manual Download

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CLUTCH

11-3

DRIVE PULLEY

REMOVAL/INSTALLATION

• Take care not to damage the drive pulley with the

strap wrench.

Hold the drive pulley [1] with a commercially available

strap wrench [2], remove the bolt (8 x 25 mm) [3] and

the drive pulley washer [4].
Apply grease to the surface [5].
Install the drive pulley, the drive pulley plate and the

bolt.
Hold the drive pulley with a commercially available strap

wrench and tighten the bolt securely.

DRIVEN PULLEY

REMOVAL/INSTALLATION

• Take care not to damage the driven pulley with the

strap wrench.

Hold the driven pulley [1] with a commercially available

strap wrench [2] and remove the bolt (8 x 20 mm) [3],

two bolts (4 x 10 mm) [4] and the driven pulley plate [5].
Install the driven pulley, the driven pulley plate and bolts

(4 x 10 mm, 8 x 20 mm) as shown.
Hold the driven pulley with a commercially available

strap wrench.
Loosely tighten the two bolts (4 x 10 mm) and tighten

the bolt (8 x 20 mm) securely.

Tighten the two bolts (4 x 10 mm) securely.

[3]

[1]

[3]

[1]

[2]

[4]

[5]

[3]

[4]

[1]

[3]

[4]

[2]

[1]

[5]

Summary of Contents for FQ650

Page 1: ...priate clothing and using safety equipment When performing any service task be especially careful of the following Read all of the instructions before you begin and make sure you have the tools the replacement or repair parts and the skills required to perform the tasks safely and completely Protect your eyes by using proper safety glasses goggles or face shields anytime you hammer drill grind or ...

Page 2: ...RMATION 2 MAINTENANCE 3 TROUBLESHOOTING 4 FUEL SYSTEM 5 GOVERNOR SYSTEM 6 IGNITION SYSTEM 7 STARTING SYSTEM 8 MUFFLER 9 ENGINE REMOVAL INSTALLATION 10 CLUTCH 11 CYLINDER HEAD 12 CYLINDER BLOCK 13 HANDLE 14 WHEEL ROTOR TRANSMISSION 15 INDEX ...

Page 3: ...How to use this manual 0 3 REVISION HISTORY No Date of revision Contents of revision 1 January 2021 Changed belt tension adjustment page 3 8 ...

Page 4: ...f course it is not practical or possible to warn you about all the hazards associated with servicing these products You must use your own good judgement Honda Motor Co Ltd 2021 You will find important safety information in a variety of forms including Safety Labels on the product Safety Messages preceded by a safety alert symbol and one of three signal words DANGER WARNING or CAUTION These signal ...

Page 5: ...e only metric tools when servicing this unit Metric bolts nuts and screws are not interchangeable with non metric fasteners The use of incorrect tools and fasteners will damage the unit SYMBOLS The symbols used throughout this manual show specific service procedures If supplementary information is required pertaining to these symbols it will be explained specifically in the text without the use of...

Page 6: ...ne Control Module EMT Exhaust Manifold Temperature EOP Engine Oil Pressure EX Exhaust F Front or Forward GND Ground HO2S Heated Oxygen sensor HST Hydrostatic Transmission IAB Intake Air Bypass IAC Idle Air Control IAT Intake Air Temperature I D Inside diameter IG or IGN Ignition IN Intake INJ Injection L Left MAP Manifold Absolute Pressure MIL Malfunction Indicator Lamp O D Outside Diameter OP Opt...

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Page 8: ...1 1 1 dummytext 1 SPECIFICATIONS SERIAL NUMBER LOCATION 1 2 SPECIFICATIONS 1 3 DIMENSIONAL DRAWINGS 1 5 WIRING DIAGRAM 1 6 ...

Page 9: ...BER LOCATION The engine serial number is located on the cylinder block The frame serial number is located on the handle column Refer to these numbers when ordering parts and when making technical inquiries ENGINE SERIAL NUMBER FRAME SERIAL NUMBER ...

Page 10: ...nclined by 25 Total displacement 196 cm3 12 0 cu in Bore and stroke 68 0 x 54 0 mm 2 68 x 2 13 in Max horsepower 4 3 kW 5 8 PS 3 600 min 1 rpm Max torque 12 4 N m 1 26 kg m 9 1 lbf ft 2 500 min 1 rpm Compression ratio 8 5 1 Cooling system Forced air Ignition system Transistorized magneto ignition Ignition timing 20 B T D C Spark plug BPR6ES NGK W20EPR U DENSO Carburetor Horizontal type butterfly v...

Page 11: ...B 38 17 x 980 BT Clutch Belt tension type Clutch operation Manual lever Transmission lubrication Oil bath Transmission oil capacity 1 2 liters 1 3 US qt 1 1 Imp qt Recommended transmission oil SAE 10W 30 API service classification SE or higher Transmission final gear ratio 1st 41 27 2nd 30 01 R 55 03 Tire size 3 50 4 4P R Recommended tire pressure 137 157 kPa 1 4 1 6 kgf cm2 19 9 22 8 psi Rotor sh...

Page 12: ...vel surface with engine bed in a level position Dimensions of overall length overall height and handle height shall be determined when locating tightening position of handle pipe middle of movable range in vertical direction 650 25 6 1 475 58 1 300 11 8 130 5 1 815 32 1 930 36 6 1 000 39 4 Unit mm in 1 000 39 4 ...

Page 13: ...SPECIFICATIONS 1 6 WIRING DIAGRAM R SPARK PLUG Bl R Bl UNIT IGNITION COIL ENGINE STOP SWITCH Bl BLACK R RED ...

Page 14: ...2 1 2 dummytext 2 SERVICE INFORMATION MAINTENANCE STANDARDS 2 2 TORQUE VALUES 2 3 LUBRICATION SEAL POINT 2 4 TOOLS 2 5 CABLE HARNESS ROUTING 2 7 TUBE ROUTING 2 8 ...

Page 15: ...18 017 0 7089 0 7093 18 07 0 711 Big end I D 30 015 30 025 1 1817 1 1821 30 066 1 1837 Big end oil clearance 0 035 0 055 0 0014 0 0022 0 12 0 005 Big end side clearance 0 80 1 40 0 031 0 055 Crankshaft Crank pin O D 29 970 29 980 1 1799 1 1803 29 920 1 1780 Valves Valve clearance IN 0 15 0 02 0 006 0 001 EX 0 20 0 02 0 008 0 001 Valve stem O D IN 5 468 5 480 0 2153 0 2157 5 318 0 2094 EX 5 425 5 4...

Page 16: ... 0 3 0 31 2 2 See page 6 3 Recoil starter set screw M6 x 1 0 Special bolt 8 8 0 90 6 5 Apply LOCTITE 262 or equivalent to the threads Item Tread Dia Torque values Remarks mm N m kgf m lbf ft Belt cover bolt M8 x 1 25 15 5 1 6 11 Inner belt cover mounting bolt M6 x 1 0 6 0 6 4 4 Handle column cover bolt M5 x 0 8 1 25 0 13 0 9 Handle column cover screw M5 Tapping 1 25 0 13 0 9 Handle column assembly...

Page 17: ...ide grease Cam shaft cam profile When new camshaft Multi purpose grease Recoil starter case boss Recoil starter case reel sliding surface Recoil starter spring inner hook Recoil starter ratchet sliding surface Recoil starter ratchet guide inside Daphne Eponex No 2 or equivalent Each oil seal rips Each O ring whole surface ThreeBond 1216E 1207B or equivalent Crankcase cover mating surface LOCTITE 2...

Page 18: ...7780 0010100 Flat cutter 28 mm 32 IN 07780 0012100 Flat cutter 25 mm 32 EX 07780 0012000 Interior cutter 26 mm 60 IN 07780 0014500 Interior cutter 22 mm 60 EX 07780 0014202 Cutter holder 5 5 mm 07781 0010101 Attachment 52 x 55 mm 07746 0010400 Attachment 37 x 40 mm 07746 0010200 Pilot 22 mm 07746 0041000 Pilot 25 mm 07746 0040600 ...

Page 19: ...SERVICE INFORMATION 2 6 Pilot 28 mm 07746 0041100 Driver 07749 0010000 Driver 22 mm I D 07746 0020100 Valve guide driver 5 5 mm 07742 0010100 Valve guide reamer 5 510 mm 07984 2000001 ...

Page 20: ... 160 mm 6 3 in HIGH TENSION CORD CARBURETOR INSULATOR IGNITION COIL CLUTCH CABLE ENGINE STOP SWITCH WIRE THROTTLE CABLE ENGINE STOP SWITCH WIRE CONNECTOR 160 mm 6 3 in ENGINE WIRE HARNESS 20 mm 0 8 in UPPER SIDE 10 mm MAX 0 4 in MAX 10 mm MAX 0 4 in MAX 160 mm 6 3 in ENGINE STOP SWITCH WIRE CLUTCH CABLE UPPER SIDE LEFT SIDE 10 mm 0 4 in 10 mm 0 4 in 90 mm 3 5 in ...

Page 21: ...SERVICE INFORMATION 2 8 TUBE ROUTING FUEL TUBE BREATHER TUBE HIGH TENSION CORD ...

Page 22: ...TMENT 3 6 CLUTCH CABLE CHECK ADJUSTMENT 3 6 BELT CHECK ADJUSTMENT 3 8 TRANSMISSION OIL LEVEL CHECK 3 10 TRANSMISSION OIL CHANGE 3 10 LUBRICATION 3 11 ENGINE IDLE SPEED CHECK ADJUSTMENT 3 11 SPARK PLUG INSPECTION ADJUSTMENT REPLACEMENT 3 12 THROTTLE CABLE CHECK ADJUSTMENT 3 13 VALVE CLEARANCE CHECK ADJUSTMENT 3 13 COMBUSTION CHAMBER CLEANING 3 14 FUEL TANK AND FILTER CLEANING 3 15 FUEL TUBE INSPECT...

Page 23: ...Every 3 months or 50 hrs Every 6 months or 100 hrs Every year or 300 hrs Engine oil Check Level 3 3 Change 3 4 Air cleaner Check 3 5 Clean 2 3 5 Replace 3 5 Tiller outside Check Throttle lever function Check Bolts and nuts tightens Check 3 6 Wiring and cables Check 2 7 Engine operation Check Tire pressure Check 3 6 Tines excessive wear damage or looseness Check Recoil starter cover Check Clean 8 2...

Page 24: ... lower level 2 on the dipstick fill with the recommended engine oil to the upper level top of the oil filler neck 3 Oil is a major factor affecting performance and service life Use 4 stroke automotive detergent oil SAE 10W 30 is recommended for general use Other viscosities shown in the chart may be used when the average temperature in your area is within the recommended range Check that the O rin...

Page 25: ...ot throw it in the trash pour it on the ground or down a drain Install the drain bolt and new sealing washer Tighten the drain bolt to the specified torque With the tiller on a level surface fill the recommended engine oil to the upper level page 3 3 Install the oil filler cap dipstick Recheck the engine oil level page 3 3 Make sure there are no engine oil leaks Used engine oil contains substances...

Page 26: ... nut 1 Air cleaner cover 2 Wing nut 3 Element Assy Grommet 4 Inner filter Paper 5 Outer filter Foam 6 Carefully check both filters for holes or tears and replace if damaged Clean the filters if they are to be reused Installation is in the reverse order of removal Clean the foam element 1 in warm soapy water rinse and allow to dry thoroughly or clean with a high flush point solvent 2 and allow to d...

Page 27: ...2 3 Check that all split pins safety clips hose clamps and cable stays are in place and properly secured TIRE INSPECTION TIRE PRESSURE ADJUSTMENT Check the tires for cuts embedded nails or other damage Check the cold tire pressure CLUTCH CABLE CHECK ADJUSTMENT CHECK Check for any deterioration or damage to the clutch cable 1 Squeeze the clutch lever 2 several times If there is a problem adjust the...

Page 28: ...ze the clutch lever 1 ten times Measure the free play at the clutch lever 1 If adjustment is necessary Loosen the lock nut 1 and adjust the clearance by turning the adjusting bolt 2 Recheck the free play After adjustment tighten the lock nut securely 1 2 4 3 Do not locate the joint area in these areas 1 FREE PLAY 2 3 mm 0 08 0 12 in 1 STANDARD CLEARANCE 8 20 mm 0 3 0 8 in 2 1 ...

Page 29: ... force more than six times as shown With the clutch engaged measure the distance L 1 between the upper and lower belt runs at the belt tensioner If the measured distance L is within specified distance L adjust the belt stopper page 3 9 If the measured distance L is out of specified distance L adjust the belt tension Loosen four engine mounting bolts 8 x 35 mm nuts 8 mm 1 and two belt stopper A bol...

Page 30: ...belt cover page 11 2 With the clutch engaged measure the clearance between the V belt 1 and four belt stoppers 2 To adjust the clearance loosen belt stopper A bolts 8 x 16 mm 3 and 4 belt stopper B bolts 6 x 12 mm 5 and 6 move the stoppers up or down as necessary and tighten the stopper bolts securely After adjusting the clearance start the engine and then disengage the clutch and make sure that t...

Page 31: ...nsmission oil into the suitable container Please dispose of used transmission oil in a manner that is compatible with the environment We suggest you take used oil in a sealed container to your local recycling center or service station for reclamation Do not throw it in the trash pour it on the ground or down a drain Install the drain plug bolt and new drain plug washer With the tiller on a level s...

Page 32: ...operating instruction Start the engine and check the idle speed If the idle speed is out of the specification turn the throttle stop screw 1 to obtain the specified standard idle speed TENSION ARM SHAFT CHANGE LEVER HOLDER HANDLE COLUMN PIVOT CLUTCH LEVER PINS RECOIL STARTER COVER BOSS RECOIL STARTER FRICTION SPRING PIN 8 x 27 mm PIN 6 x 24 mm DISASSEMBLY ASSEMBLY page 8 4 DISASSEMBLY ASSEMBLY pag...

Page 33: ...alent Replace the spark plug if the sealing washer is damaged Measure the plug gap with a thickness gauge If the measurement is out of the specification adjust by bending the side electrode Install the spark plug finger tight to seat the washer then tighten it to the specified torque A loose spark plug can become very hot and can damage the engine Overtightening can damage the threads in the cylin...

Page 34: ... spark plug cap 1 and remove the breather tube 2 Remove the head cover bolts 3 cylinder head cover 4 cylinder head cover gasket 5 When removing the cylinder head cover pry off slowly at each corner of the head cover Using too much force can deform the cylinder head cover The cylinder head cover must be replaced if it is deformed Align the square hole 1 with mark on the starter pulley 2 with the to...

Page 35: ... lock nut 6 mm 2 to the specified torque Recheck the valve clearance and if necessary readjust the clearance Installation is in the reverse order of removal Check the V belt tension page 3 8 COMBUSTION CHAMBER CLEANING Remove the cylinder head page 12 3 Clean any carbon deposits from the combustion chamber 1 Install the cylinder head page 12 3 VALVE CLEARANCE IN 0 15 0 02 mm 0 006 0 001 in EX 0 20...

Page 36: ...e there are no fuel leaks FUEL TUBE INSPECTION Remove the fan cover page 8 2 Check the fuel tube 1 for damage fuel leakage corrosion and other abnormalities Check that the fuel tube is not interfering with the neighboring parts Replace the fuel tube if there is damage fuel leakage or corrosion page 5 3 Install the fan cover page 8 2 Gasoline is highly flammable and explosive You can be burned or s...

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Page 38: ...4 1 4 dummytext 4 TROUBLESHOOTING BEFORE TROUBLESHOOTING 4 2 ENGINE TROUBLESHOOTING 4 2 FRAME TROUBLESHOOTING 4 5 ...

Page 39: ...e connected securely Check for sufficient fresh fuel in the fuel tank ENGINE TROUBLESHOOTING ENGINE DOES NOT CRANK Remove the recoil starter page 8 2 and check whether the engine cranks Cannot be cranked Abnormal Cranks Inspect the recoil starter page 8 2 Disassemble the engine and replace the faulty part s page 13 4 Replace the faulty part s ...

Page 40: ...ge 12 7 Valve seat width page 12 6 Valve face irregularly worn page 12 7 Decompressor operation page 13 12 Piston ring side clearance page 13 8 Piston ring width page 13 9 Piston ring end gap page 13 9 Piston skirt O D page 13 7 Cylinder sleeve I D page 13 6 Disassemble the carburetor to clean the carburetor ports jets and nozzles page 5 6 Wet Spark No spark Fuel No fuel Perform the spark test pag...

Page 41: ...osits in the combustion chamber page 3 14 Check around the air intake joint and carburetor replace the insulator and or gasket if necessary Disassemble and clean the carburetor page 5 7 Inspect the spark plug and adjust the spark plug gap page 3 12 Replace if necessary page 3 12 Adjust the valve clearance page 3 13 Clogged Abnormal Air leaking Compression is too high Compression is too low No air ...

Page 42: ...ch cable misadjusted Adjust page 3 6 V belt misadjusted Adjust page 3 8 Tension arm binding on tension arm shaft Clean and lubricate page 15 11 Check the wire harness connecting the engine stop switch and the ignition coil for open or short circuit Replace the engine wire harness Check the ignition coil primary side page 7 7 Replace the ignition coil if abnormalities are found and recheck Abnormal...

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Page 44: ...ALLATION 5 3 AIR CLEANER REMOVAL INSTALLATION 5 4 CARBURETOR REMOVAL INSTALLATION 5 5 CARBURETOR DISASSEMBLY ASSEMBLY 5 6 CARBURETOR BODY CLEANING 5 7 CARBURETOR INSPECTION 5 7 PILOT SCREW REPLACEMENT 5 8 CHOKE REPLACEMENT 5 9 CARBURETOR STUD BOLT REPLACEMENT 5 9 ...

Page 45: ...FUEL SYSTEM 5 2 FUEL SYSTEM TOOLS Float level gauge 07401 0010000 ...

Page 46: ...ndling fuel Keep heat sparks and flame away Handle fuel only outdoors Wipe up spills immediately 1 2 FUEL FILTER JOINT FUEL TANK BOLT 6 x 34 mm FUEL FILLER CAP O RING FUEL TANK FUEL TUBE CHECK Check for deterioration cracks or clogs FUEL FILLER CAP PACKING CHECK Check for deterioration or cracks NUT 6 mm 2 CHECK Check the screen of the fuel tank joint for clogs or damage FUEL STRAINER When reassem...

Page 47: ...BOW AIR CLEANER COVER WING NUT WING NUT GROMMET BREATHER TUBE COLLAR BOLT 6 x 20 mm INNER FILTER PAPER OUTER FILTER FOAM AIR CLEANER ELBOW SEAL AIR CLEANER ELBOW NUT 6 mm 2 AIR CLEANER COLLAR 2 REMOVAL INSTALLATION Remove and install the air cleaner elbow with the fuel valve lever in the OFF position and the choke lever in the CLOSE position Before installation clean the inside of the air cleaner ...

Page 48: ...CKING CARBURETOR PACKING CARBURETOR INSULATOR FUEL TUBE REMOVAL INSTALLATION Pull the carburetor to a point where the groove 1 of the throttle arm lines up with the governor rod 2 and then lift the governor rod out of the hole of the throttle arm and unhook the throttle return spring 3 2 3 TUBE CLIP CARBURETOR 1 TUBE CLAMP INSTALLATION Before installing clean the passage 1 thoroughly with compress...

Page 49: ...EMBLY Before installing clean thoroughly with low pressure compressed air Lightly lubricate the O ring 1 to ensure easy installation into the carburetor body ASSEMBLY Before installing clean thoroughly with low pressure compressed air FLOAT CHAMBER ASSEMBLY Install the float chamber to the carburetor body at an angle as shown UPPER SIDE UPPER SIDE ADJUSTMENT page 3 11 LIMITER CAP O RING FLOAT FLOA...

Page 50: ...ompressed air Pilot screw hole 1 Pilot jet hole 2 Pilot air jet 3 Main air jet 4 Transition ports 5 Pilot outlet 6 Main nozzle holder 7 External vent port 8 Internal vent port 9 CARBURETOR INSPECTION FLOAT LEVEL HEIGHT Place the carburetor in the position as shown Measure the distance between the float top and carburetor body when the float just contacts the seat without compressing the valve spri...

Page 51: ...placement pilot screw and install it on the carburetor Turn the pilot screw in until it is lightly seated and then turn the screw out the required number of turns Refer to the table above for carburetor pilot screw initial opening setting Apply LOCTITE 638 or equivalent to the inside of the limiter cap and then install the cap so the stop prevents the pilot screw from being turned counterclockwise...

Page 52: ...o the slit 3 of the choke shaft Be sure the choke shaft is in the position between the projections 4 of the choke valve plate CARBURETOR STUD BOLT REPLACEMENT Remove the carburetor page 5 5 Thread two nuts onto the carburetor stud bolts 1 and tighten them together then use a wrench to turn the stud bolt out Install and tighten new stud bolts until they are fully seated 1 2 4 2 3 2 1 4 1 ...

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Page 54: ...6 1 6 dummytext 6 GOVERNOR SYSTEM CONTROL BASE GOVERNOR ARM REMOVAL INSTALLATION 6 2 GOVERNOR ADJUSTMENT 6 3 GOVERNOR REMOVAL INSTALLATION 6 4 ...

Page 55: ...OVERNOR ARM PINCH BOLT GOVERNOR ARM NUT 6 mm THROTTLE CABLE When reassembly install the spring with the long end side toward the control base INSTALLATION Hook the throttle return spring on the hole marked H ADJUSTMENT page 6 3 GOVERNOR ROD THROTTLE RETURN SPRING REMOVAL INSTALLATION Pull the carburetor to a point where the groove 1 of the throttle arm lines up with the governor rod 2 and then lif...

Page 56: ... tank page 5 3 Use a tachometer with graduations of 50 min 1 rpm or smaller that will accurately indicate a 50 min 1 rpm change Warm up the engine Stop the engine and connect a tachometer according to manufacturer s operating instruction Start the engine and bring the engine to its standard speed with the throttle lever Adjust the throttle control screw 4 so that the throttle cannot be moved past ...

Page 57: ...N Spread the governor weights to install the governor slider CHECK After installing the governor slider check to be sure it moves smoothly Gear and sliding surface CHECK After installing the governor weights check to be sure they move freely GOVERNOR HOLDER CLIP INSTALLATION Install firmly into the groove of the governor holder shaft LOCK PIN INSTALLATION Install firmly into the groove of the gove...

Page 58: ...SYSTEM TROUBLESHOOTING 7 2 IGNITION COIL REMOVAL INSTALLATION 7 3 COOLING FAN FLYWHEEL REMOVAL INSTALLATION 7 4 IGNITION COIL AIR GAP CHECK ADJUSTMENT 7 6 SPARK PLUG CAP INSPECTION 7 6 IGNITION COIL INSPECTION 7 7 SPARK TEST 7 7 ENGINE STOP SWITCH REMOVAL INSTALLATION 7 8 ...

Page 59: ...LUG Check the following before troubleshooting Loose connectors Spark plug page 3 12 Engine oil level page 3 3 Replace the engine stop switch page 7 8 Check for continuity between the engine wire harness connectors Replace the engine wire harness Check the engine stop switch page 7 9 Check the ignition coil page 7 7 Replace the ignition coil page 7 3 Abnormal Abnormal Abnormal Normal Normal Normal...

Page 60: ...n cover page 8 2 Carburetor page 5 5 Route the engine wire harness and high tension code properly page 2 8 After installation check the ignition coil air gap page 7 6 BOLT 6 x 25 mm 2 IGNITION COIL IGNITION COIL CONNECTOR HIGH TENSION CORD ENGINE WIRE HARNESS INSPECTION page 7 7 ...

Page 61: ...le tool 1 to remove the flywheel REMOVAL Hold the flywheel 1 with a commercially available strap wrench 2 being careful not to damage the magnet part Remove the flywheel nut 14 mm 3 NUT 14 mm WOODRUFF KEY MAGNET PART SIDE PLATE BOLT 6 x 22 mm STARTER PULLEY COOLING FAN 1 2 3 FLYWHEEL 1 75 N m 7 5 kgf m 55 lbf ft Threads and seating surface ...

Page 62: ...fan 1 to the flywheel 2 by aligning the four projections of the cooling fan with the holes of the flywheel Attach the starter pulley 3 by aligning the following Holes of the pulley and tabs of the cooling fan Tab of the pulley and hole of the flywheel Apply a light coat of engine oil to the threads and the seating surface of the nut 1 and loosely tighten the nut Hold the flywheel 2 with a commerci...

Page 63: ...ert the feeler gauge of proper thickness between the ignition coil and flywheel Push the ignition coil firmly against the flywheel and tighten the ignition coil bolts securely Remove the feeler gauge SPARK PLUG CAP INSPECTION Measure the resistance of the spark plug cap 1 by attaching one ohmmeter probe to the terminal in the spark plug cap and the other to the high tension cord terminal If measur...

Page 64: ...y attaching one ohmmeter probe to the high tension cord and the other at the iron core 2 If measured resistance is out of specification replace the ignition coil SPARK TEST Inspect the following before performing spark test Faulty spark plug Loose spark plug cap Water in the spark plug cap Leaking the ignition coil secondary voltage Remove the spark plug cap page 3 12 Connect a known good spark pl...

Page 65: ...G SCREW 4 mm 2 1 5 N m 0 15 kgf m 1 1 lbf ft BAND ENGINE STOP SWITCH WIRE ENGINE STOP SWITCH WIRE CONNECTOR When reassembly position to the specified range page 2 7 INSPECTION page 7 9 ENGINE STOP SWITCH GROUND TERMINAL BOLT 5 x 10 mm 3 N m 0 31 kgf m 2 2 lbf ft INSTALLATION Be sure to tighten with correct side of ground terminal up Tighten so that no bend or overlap occur UP ...

Page 66: ...EM 7 9 ENGINE STOP SWITCH INSPECTION Check for continuity between the engine stop switch wire connector 1 and ground terminal 2 in each switch position Switch position Continuity ON No Continuity OFF Continuity 1 2 ...

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Page 68: ...8 1 8 dummytext 8 STARTING SYSTEM RECOIL STARTER REMOVAL INSTALLATION 8 2 RECOIL STARTER INSPECTION 8 2 RECOIL STARTER DISASSEMBLY ASSEMBLY 8 4 ...

Page 69: ... two ratchets 1 by pulling the starter rope out several times Pull the starter grip 2 until the starter rope 3 is pulled out fully Check the rope for fraying or wearing Clean the recoil starter cover 4 to remove the dirt and debris Install the recoil starter page 8 2 RECOIL STARTER ASSEMBLY BOLT 6 x 10 mm 7 INSPECTION page 8 2 DISASSEMBLY ASSEMBLY page 8 4 FAN COVER 1 3 4 2 ...

Page 70: ...STARTING SYSTEM 8 3 STARTER PULLEY Remove the recoil starter page 8 2 Inspect the six square holes 1 of the starter pulley 2 for deformation Install the recoil starter page 8 2 2 1 1 ...

Page 71: ...During disassembly assembly take care not to allow the spring to come out SET SCREW 8 8 N m 0 90 kgf m 6 5 lbf ft RATCHET GUIDE FRICTION SPRING STARTER RATCHET 2 RETURN SPRING 2 RECOIL STARTER REEL RECOIL STARTER ROPE RECOIL STARTER SPRING RECOIL STARTER CASE STARTER KNOB Reel sliding surface and boss Sliding surface inside Inner hook ...

Page 72: ...ok the outer hook 1 of the recoil starter spring 2 to the groove 3 of the recoil starter reel 4 and then install the recoil starter spring by winding it Apply grease to the boss 1 of the recoil starter case 2 Set the recoil starter reel 3 to the recoil starter case by aligning the inner hook 4 of the recoil starter spring with the cutout of the recoil starter case Wear gloves and eye protection Du...

Page 73: ...ing agent LOCTITE 262 or equivalent to the threads of the set screw 3 Hold the ratchet guide and tighten the set screw to the specified torque Turn the recoil starter reel 1 more than 2 turns counterclockwise to preload the recoil starter spring Be sure to hold the recoil starter reel Pass the recoil starter rope through hole 1 of the recoil starter case the starter knob 2 and then tie the rope as...

Page 74: ...9 1 9 dummytext 9 MUFFLER MUFFLER REMOVAL INSTALLATION 9 2 ...

Page 75: ...removal must be made while the engine is cold MUFFLER PROTECTOR MUFFLER DEFLECTOR GASKET MUFFLER HEX NUT 8 mm 2 24 N m 2 4 kgf m 18 lbf ft MUFFLER PROTECTOR SCREW 5 x 8 mm 4 3 N m 0 31 kgf m 2 2 lbf ft MUFFLER DEFLECTOR MOUNTING SCREW 4 x 6 mm 2 2 N m 0 20 kgf m 1 5 lbf ft MUFFLER MUFFLER STAY BOLT 6 x 13 mm 12 N m 1 2 kgf m 9 lbf ft Before installation remove the carbon deposits with a plastic ha...

Page 76: ...10 1 10 dummytext 10 ENGINE REMOVAL INSTALLATION ENGINE REMOVAL INSTALLATION 10 2 ...

Page 77: ...installation adjust the V belt tension page 3 8 Remove the tension arm page 11 2 Remove the air cleaner elbow page 5 4 Move the throttle lever to the LOW position and disconnect the throttle cable 1 from the control plate 2 1 2 THROTTLE CABLE ENGINE STOP SWITCH WIRE CONNECTOR NUT 8 mm 4 BOLT 8 x 35 mm 4 WIRE HARNESS BAND ENGINE STOP SWITCH WIRE CONNECTOR ...

Page 78: ...11 1 11 dummytext 11 CLUTCH PULLEY V BELT REMOVAL INSTALLATION 11 2 ...

Page 79: ... 20 mm DRIVEN PULLEY DRIVE PLLEY WASHER INNER BELT COVER BOLT 6 x 12 mm 6 N m 0 6 kgf m 4 4 lbf ft DRIVE PULLEY DRIVE PULLEY BOLT 8 x 25 mm TENSION ARM DRIVEN PLLEY PLATE BELT STOPPER A BOLT 8 x 16 mm 2 ADJUSTMENT page 3 9 ADJUSTMENT page 3 9 REMOVAL INSTALLATION page 11 3 REMOVAL INSTALLATION page 11 3 Before installation check that there is no crack and abnormal wear out in the belt and replace ...

Page 80: ...h and tighten the bolt securely DRIVEN PULLEY REMOVAL INSTALLATION Take care not to damage the driven pulley with the strap wrench Hold the driven pulley 1 with a commercially available strap wrench 2 and remove the bolt 8 x 20 mm 3 two bolts 4 x 10 mm 4 and the driven pulley plate 5 Install the driven pulley the driven pulley plate and bolts 4 x 10 mm 8 x 20 mm as shown Hold the driven pulley wit...

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Page 82: ...LINDER HEAD TOOLS 12 2 CYLINDER HEAD REMOVAL INSTALLATION 12 3 CYLINDER HEAD DISASSEMBLY ASSEMBLY 12 4 CYLINDER HEAD VALVES INSPECTION 12 5 VALVE GUIDE REPLACEMENT 12 8 VALVE GUIDE REAMING 12 9 VALVE SEAT RECONDITIONING 12 9 ...

Page 83: ...m 45 IN 07780 0010200 Seat cutter 24 5 mm 45 EX 07780 0010100 Flat cutter 28 mm 32 IN 07780 0012100 Flat cutter 25 mm 32 EX 07780 0012000 Interior cutter 26 mm 60 IN 07780 0014500 Interior cutter 22 mm 60 EX 07780 0014202 Cutter holder 5 5 mm 07781 0010101 Valve guide reamer 5 510 mm 07984 2000001 ...

Page 84: ... page 9 2 After installation inspect following Valve clearance page 3 13 Cylinder compression page 12 5 Threads and seating surface CYLINDER HEAD BOLT 8 x 60 mm 4 24 N m 2 4 kgf m 18 lbf ft HEAD COVER BOLT 6 x 12 mm 4 BOLT 6 x 12 mm 2 SHROUD CYLINDER HEAD REMOVAL INSTALLATION Loosen and tighten the bolts in a crisscross pattern in 2 3 steps CYLINDER HEAD COVER CYLINDER HEAD COVER PACKING CYLINDER ...

Page 85: ...M PIVOT 2 VALVE ROCKER ARM ROCKER ARM PIVOT BOLT 2 PUSH ROD GUIDE PLATE PUSH ROD VALVE STEM SEAL Sliding surface and stem end INTAKE VALVE Sliding surface and stem end INSPECTION page 12 7 INSTALLATION Do not interchange with the intake valve The exhaust valve is smaller than the intake valve SPARK PLUG INSPECTION page 3 12 INSPECTION page 12 7 VALVE SPRING 2 CLIP VALVE SPRING RETAINER REMOVAL Pus...

Page 86: ... unburned gas Attach a commercially available compression gauge 1 to the spark plug hole Pull the recoil starter forcefully to measure stable cylinder compression CYLINDER HEAD WARPAGE Check the spark plug hole and valve areas for cracks Clean any gasket material from the cylinder head mating surface and check the cylinder head warpage using a straightedge 1 and feeler gauge 2 Be careful not the d...

Page 87: ...er the valve seat contact area of the valve is too high or too low If the valve seat is too high or too low recondition the valve seat page 12 10 VALVE GUIDE I D Ream the valve guide to remove any carbon deposits before measuring the guide 1 I D Turn the valve guide reamer special tool clockwise never counterclockwise Continue to rotate the special tool while removing it from the valve guide Measu...

Page 88: ...t replace the valve and cylinder head as a set page 12 4 VALVE SPRING FREE LENGTH PERPENDICULARITY Measure the valve spring free length If the measured length is less than the service limit replace the valve spring Measure the valve spring perpendicularity If the measured perpendicularity is more than the service limit replace the valve spring STANDARD IN 5 468 5 480 mm 0 2153 0 2157 in EX 5 425 5...

Page 89: ...ot use a torch to heat the cylinder head warpage of the cylinder head may result Do not get the cylinder head hotter than 150 C 300 F excessive heat may loosen the valve seat Remove the heated cylinder head from the hot plate and support it with wooden blocks Drive the valve guides 1 out of the cylinder head from the combustion chamber side When driving the valve guides out be careful not to damag...

Page 90: ...cutting oil Rotate the reamer clockwise through the valve guide the full length of the reamer Turn the special tool valve guide reamer clockwise never counterclockwise Continue to rotate the special tool while removing it from the valve guide Thoroughly clean the cylinder head to remove any cutting residue Check the valve guide bore it should be straight round and centered in the valve guide Inser...

Page 91: ... finished valve seat is within specification Lap the valves into their seats using a commercially available valve lapper and lapping compound After lapping wash all residual compound off the cylinder head and valve Do not push the valve against the seat with force during lapping Apply a light pass with the valve lapper Avoid lapping the valve in the same position as it causes uneven wear Lap the v...

Page 92: ...SE COVER REMOVAL INSTALLATION 13 3 CRANKSHAFT CAMSHAFT PISTON REMOVAL INSTALLATION 13 4 PISTON DISASSEMBLY ASSEMBLY 13 5 CRANKCASE COVER CYLINDER BARREL PISTON CONNECTING ROD CRANKSHAFT CAMSHAFT INSPECTION 13 6 CRANKSHAFT BEARING OIL SEAL REPLACEMENT 13 13 ...

Page 93: ...CYLINDER BLOCK 13 2 CYLINDER BLOCK TOOLS Attachment 37 x 40 mm 07746 0010200 Attachment 52 x 55 mm 07746 0010400 Pilot 25 mm 07746 0040600 Driver 07749 0010000 ...

Page 94: ...al lips Clean the mating surface and apply a bead 2 0 2 5 mm 0 08 0 10 in of liquid sealant ThreeBond 1216E 1207B or equivalent as shown Install the cover within 3 minutes after application Pouring the engine oil is performed after 30 minutes have elapsed from assembling CRANKSHAFT BEARING 6205 OIL SEAL Lips CRANKCASE COVER BOLT 8 x 32 mm 6 24 N m 2 4 kgf m 18 lbf ft OIL FILLER CAP PACKING CHECK R...

Page 95: ...timing gear 1 of the crankshaft and camshaft 2 by aligning the punch marks 3 PISTON Outer surface and big end bearing OIL SEAL Lips VALVE LIFTER Stem stem end and slipper surface Cam profile and journal Big end bearing CONNECTING ROD BOLT 7 x 32 mm 2 12 N m 1 2 kgf m 9 lbf ft Threads and seating surface CAMSHAFT Pin and gear teeth 3 1 2 Cylinder inner surface CYLINDER BARREL REMOVAL Mark the valve...

Page 96: ...d second ring 4 are not interchanged Install the top ring and second ring on the piston with the maker mark side facing up Check that the piston rings rotate smoothly after installing them Space the piston ring end gaps 120 apart and do not align the ring end gaps with the piston pin bore INSTALLATION Install by setting one end of the piston pin clip in the groove of the piston pin bore holding th...

Page 97: ... replace the cylinder barrel Inspect the camshaft O D page 13 12 CYLINDER SLEEVE I D Measure and record the cylinder I D at three levels in both the X axis perpendicular to crankshaft and the Y axis parallel to crankshaft Take the maximum reading to determine cylinder wear and taper If the measurement is more than the service limit replace the cylinder barrel Inspect the piston skirt O D page 13 7...

Page 98: ...lated clearance is more than the service limit replace the piston and recheck the clearance If the clearance is still more than the service limit with a new piston replace the cylinder barrel PISTON PIN BORE I D Measure and record the piston pin bore I D of the piston If the measurement is more than the service limit replace the piston Inspect the piston pin O D page 13 8 STANDARD 67 965 67 982 mm...

Page 99: ...ervice limit with a new piston pin replace the piston PISTON RING SIDE CLEARANCE Measure the clearance between each piston ring and ring groove of the piston using a feeler gauge If any of the measurements is more than the service limit inspect the piston ring width If the piston ring width is normal replace the piston and recheck the clearance If necessary replace the piston rings top second oil ...

Page 100: ...ton rings top second oil as a set CONNECTING ROD BIG END SIDE CLEARANCE Measure the clearance between the connecting rod big end and crankshaft using a feeler gauge If necessary replace the connecting rod and or crankshaft STANDARD Top 0 95 0 97 mm 0 037 0 038 in Second 0 94 0 96 mm 0 037 0 038 in SERVICE LIMIT Top 0 93 mm 0 037 in Second 0 92 mm 0 036 in STANDARD Top 0 200 0 350 mm 0 0079 0 0138 ...

Page 101: ...hten the connecting rod bolts to the specified torque Measure the connecting rod big end I D If the measurement is more than the service limit replace the connecting rod page 13 5 CRANKPIN O D Measure the crankpin O D of the crankshaft If the measurement is less than the service limit replace the crankshaft STANDARD 18 006 18 017 mm 0 7089 0 7093 in SERVICE LIMIT 18 07 mm 0 711 in TORQUE 12 N m 1 ...

Page 102: ...gauge is in place Remove the connecting rod and measure the plastigauge If the clearance is more than the service limit inspect the connecting rod big end I D and the crankpin O D If necessary replace the part that is not within the service limit and recheck the clearance CRANKSHAFT RUNOUT Set the crankshaft on V blocks and measure the runout using a dial indicator If the measured runout is more t...

Page 103: ...mshaft DECOMPRESSOR WEIGHT Check for worn and weakened spring If the weight return spring 1 is worn or weakened replace it Check that the decompressor weight moves smoothly If the decompressor weight does not move correctly replace the camshaft STANDARD IN 27 500 27 900 mm 1 0827 1 0984 in EX 27 547 27 947 mm 1 0845 1 1003 in SERVICE LIMIT IN 27 45 mm 1 081 in EX 27 50 mm 1 083 in STANDARD 13 966 ...

Page 104: ...Cylinder block side Drive out the bearing 6205 from the cylinder block page 13 4 Drive out the bearing 6205 from the crankcase cover page 13 3 Drive a new bearing 1 with its marked side facing up until it is fully seated on the end using the special tools Crankcase cover side TOOLS Attachment 52 x 55 mm 2 07746 0010400 Pilot 25 mm 3 07746 0040600 Driver 4 07749 0010000 CYLINDER BLOCK SIDE CRANKCAS...

Page 105: ... to the lips of a new oil seal 25 x 41 x 6 mm 1 Drive the oil seal in the position as shown with its flat surface side facing up using the special tools Crankcase cover side TOOLS Attachment 37 x 40 mm 2 07746 0010200 Driver 3 07749 0010000 INSTALLATION HEIGHT Cylinder block side 1 5 mm 0 06 in Crankcase cover side 5 5 mm 0 22 in CYLINDER BLOCK SIDE CRANKCASE COVER SIDE 1 5 mm 0 06 in 3 1 2 5 5 mm...

Page 106: ... 1 14 dummytext 14 HANDLE HANDLE COLUMN ASSEMBLY REMOVAL INSTALLATION 14 2 HANDLE COLUMN DISASSEMBLY ASSEMBLY 14 3 CLUTCH LEVER DISASSEMBLY ASSEMBLY 14 4 THROTTLE LEVER ASSEMBLY REMOVAL INSTALLATION 14 5 ...

Page 107: ...alling the handle column assembly route the wire harness properly page 2 7 THROTTLE CABLE CABLE BAND HANDLE COLUMN ASSEMBLY CLUTCH CABLE ENGINE STOP SWITCH WIRE CONNECTOR THROTTLE LEVER ENGINE STOP SWITCH CLUTCH LEVER BOLT 8 x 20 mm 4 24 N m 2 4 kgf m 18 lbf ft REMOVAL INSTALLATION page 14 5 DISASSEMBLY ASSEMBLY page 14 3 REMOVAL INSTALLATION page 7 8 DISASSEMBLY ASSEMBLY page 14 4 ...

Page 108: ...E HANDLE COLUMN COVER LOWER CHANGE LEVER BOLT 6 x 12 mm 2 LOCK PIN RETURN SPRING BOLT 6 x 12 mm PIN UPPER CHANGE LEVER SPRING WASHER GROMMET BOLT 6 x 12 mm When reassembly install the handle lock nut tab into the handle pipe hole When reassembly apply ThreeBond 1530C or equivalent to the inside When reassembly apply grease to the sliding surface REASSEMBLY Install the long side against the handle ...

Page 109: ...LUTCH CABLE PIN 8 x 27 mm PIN 6 x 24 mm CLUTCH LEVER L HANDLE GRIP SPLIT PIN 1 6 mm 2 Align When reassembly apply ThreeBond 1530C or equivalent to the inside When reassembly apply grease to the sliding surface When reassembly apply grease to the sliding surface ...

Page 110: ...THROTTLE CABLE SCREW 5 x 25 mm 2 5 N m 0 25 kgf m 1 8 lbf ft CONTROL PLATE HANDLE PIPE R HANDLE GRIP BAND NUT 5 mm When reassembly position to the specified range page 2 7 BAND When reassembly position to the specified range page 2 7 When reassembly apply ThreeBond 1530C or equivalent to the inside When reassembly position to the specified range page 2 7 BAND When reassembly position to the specif...

Page 111: ...MEMO ...

Page 112: ...MOVAL INSTALLATION 15 6 FRENCH ROTOR DISASSEMBLY ASSEMBLY 15 7 FRENCH ROTOR ASSEMBLY CHECK 15 9 SUB FENDER REMOVAL INSTALLATION 15 10 TRANSMISSION MAIN FENDER ENGINE BED REMOVAL INSTALLATION 15 11 TRANSMISSION DISASSEMBLY ASSEMBLY 15 12 FRONT STAND FRONT PIPE GUARD REMOVAL INSTALLATION 15 16 FRONT STAND DISASSEMBLY ASSEMBLY 15 17 ...

Page 113: ...WHEEL ROTOR TRANSMISSION 15 2 WHEEL ROTOR TRANSMISSION TOOLS Pilot 22 mm 07746 0041000 Pilot 28 mm 07746 0041100 Driver 07749 0010000 Driver 22 mm I D 07746 0020100 ...

Page 114: ...EEL REMOVAL INSTALLATION The R wheel and L wheel can be removed in the same manner R wheel shown Up side view Front SHAFT PIN 8 x 40 mm R WHEEL When installation note the installation direction DISASSEMBLY ASSEMBLY page 15 4 LOCK PIN ...

Page 115: ...EMBLY ASSEMBLY WHEEL DISASSEMBLY For disassembling the wheel push the valve core and decrease the air pressure BOLT 8 x 20 mm 4 OUTER SIDE RIM TIRE 3 50 4 4P R VALVE CAP TIRE TUBE INNER SIDE RIM NUT 8 mm 4 VALVE CORE SPRING WASHER 4 WHEEL SHAFT ...

Page 116: ... shaft 6 as shown Take care not to pinch the tube Install the four bolts 8 x 20 mm 1 spring washers 2 and nuts 8 mm 3 Tighten the nuts securely in the specified sequence as shown Apply air pressure to the valve 4 to specified air pressure Install the valve cap 5 1 R wheel 4 3 2 4 3 1 2 L wheel 5 5 6 6 RECOMMENDED TIRE PRESSURE 137 157 kPa 1 4 1 6 kgf cm2 19 9 22 8 psi 5 2 1 4 1 4 2 3 3 ...

Page 117: ...r installation make sure that the right and left rotors are symmetry page 15 9 R FRENCH ROTOR LOCK PIN Right side shown MARKS TRANSMISSION MARK TRANSMISSION DISASSEMBLY ASSEMBLY page 15 7 When installation make sure that the R and L marks are facing up When installation make sure that the R and L marks are facing up SHAFT PIN 8 x 40 mm ...

Page 118: ...d TINE H 2 Tine G shape 6 Tine H shape 6 TINE G 2 FRENCH ROTOR NUT 8 mm 4 26 5 N m 2 7 kgf m 20 lbf ft FRENCH ROTOR NUT 8 mm 4 26 5 N m 2 7 kgf m 20 lbf ft BOLT 8 x 20 mm 4 TINE H 2 TINE G 2 FRENCH ROTOR NUT 8 mm 4 26 5 N m 2 7 kgf m 20 lbf ft BOLT 8 x 20 mm 4 BOLT 8 x 20 mm 4 R ROTOR PIPE TINE G 2 TINE H 2 R MARK Inward IDENTIFICATION MARKS CHECK page 15 9 ...

Page 119: ...Tine H shape 6 TINE H 2 FRENCH ROTOR NUT 8 mm 4 26 5 N m 2 7 kgf m 20 lbf ft FRENCH ROTOR NUT 8 mm 4 26 5 N m 2 7 kgf m 20 lbf ft BOLT 8 x 20 mm 4 TINE H 2 TINE G 2 FRENCH ROTOR NUT 8 mm 4 26 5 N m 2 7 kgf m 20 lbf ft BOLT 8 x 20 mm 4 BOLT 8 x 20 mm 4 L ROTOR PIPE TINE H 2 TINE G 2 TINE G 2 IDENTIFICATION MARKS L MARK Inward CHECK page 15 9 ...

Page 120: ...ANSMISSION 15 9 FRENCH ROTOR ASSEMBLY CHECK Check that the tines are assembled properly as shown The right rotor and left rotor are symmetry Out side view L ROTOR ASSEMBLY R ROTOR ASSEMBLY Out side view G MARK H MARK ...

Page 121: ...WHEEL ROTOR TRANSMISSION 15 10 SUB FENDER REMOVAL INSTALLATION Left side only Remove the belt cover page 11 2 Left side shown SUB FENDER BACK BRACKET COLLAR 3 BUSH 3 NUT 6 mm 5 BOLT 6 x 12 mm 5 ...

Page 122: ...lumn page 14 2 TENSIONER ARM SHAFT HITCH PIN DRAG BAR HITCH ATTACHMENT HITCH BOX BOLT 8 x 16 mm 2 MAIN FENDER R CASE PROTECTOR BOLT 8 x 32 mm 2 LOCK PIN BOLT 8 x 65 mm 2 L CASE PROTECTOR BOLT 8 x 65 mm 2 BOLT 10 x 85 mm TRANSMISSION ENGINE BED BOLT 8 x 30 mm 2 NUT 10 mm FENDER COLLAR 2 BOLT 8 x 25 mm 2 SHAFT PIN LOCK PIN Sliding surface NUT 8 mm 9 ...

Page 123: ...llation direction Front side TRANSMISSION TOP COVER BOLT 6 x 12 mm 2 CASE O RING PLUG SEAL 28 mm 2 PLUG SEAL 16 2 mm OIL SEAL 12 x 22 x 6 mm INPUT SHAFT BEARING 6202 2 INTERNAL CIRCLIP 35 mm OIL SEAL 15 x 35 x 7 mm BEARING HOLDER PLATE BOLT 6 x 12 mm 3 11 N m 1 1 kgf m 8 lbf ft O RING 39 x 2 6 mm DISTANCE COLLAR B COUNTERSHAFT COLLAR COUNTERSHAFT SECOND GEAR COUNTERSHAFT WASHER COUNTERSHAFT FIRST ...

Page 124: ...the left side WHEEL SHAFT FINAL GEAR BEARING 6202 DRIVEN SPROCKET FINAL CHAIN RK502KF x 44LE LEFT SIDE RIGHT SIDE REAR SIDE FRONT SIDE TRANSMISSION CASE BEARING 6005 PLUG SEAL 28 mm O RING 43 5 x 2 6 mm DISTANCE COLLAR A COUNTERSHAFT BEARING 6203 DRAIN PLUG BOLT FINAL SHAFT COLLAR REVERSE IDLE GEAR WATER SEAL 25 x 52 x 9 5 mm O RING OIL FILLER CAP DRAIN PLUG WASHER When reassembly apply transmissi...

Page 125: ... Drive a new plug seal 28 mm 1 from outside until it is flush with the transmission case surface by using the special tools PLUG SEAL 16 2 mm OIL SEAL 12 x 22 x 6 mm Drive a new plug seal 16 2 mm oil seal 12 x 22 x 6 mm from outside until it is flush with the transmission case surface by using the special tools TOOLS Pilot 28 mm 2 07746 0041100 Driver 3 07749 0010000 2 3 1 1 0 mm 0 04 in TOOLS Plu...

Page 126: ... using the special tool and hydraulic press SHIFT FORK SHAFT INSTALLATION Push the steel ball 1 into the transmission case 2 against the spring 3 with the suitable rod 4 and insert the shift fork shaft 5 TRANSMISSION OIL FILLING Fill the specified amount of recommended transmission oil into the transmission case TOOL Driver 22 mm I D 2 07746 0020100 2 1 TOOL Driver 22 mm I D 3 07746 0020100 3 1 2 ...

Page 127: ...WHEEL ROTOR TRANSMISSION 15 16 FRONT STAND FRONT PIPE GUARD REMOVAL INSTALLATION FRONT STAND NUT 10 mm 2 FRONT PIPE GUARD BOLT 8 x16 mm 4 BOLT 10 x 75 mm 2 ...

Page 128: ...WHEEL ROTOR TRANSMISSION 15 17 FRONT STAND DISASSEMBLY ASSEMBLY Remove the front stand page 15 16 MAIN PIPE WASHER 10 mm 2 HANDLE RUBBER BOLT 10 x 45 mm MOUNT BASE LOCK NUT 10 mm RETURN SPRING 2 ...

Page 129: ...MEMO ...

Page 130: ... FUEL TANK REMOVAL INSTALLATION 5 3 FUEL TUBE INSPECTION 3 15 G GOVERNOR ADJUSTMENT 6 3 GOVERNOR REMOVAL INSTALLATION 6 4 H HANDLE COLUMN ASSEMBLY REMOVAL INSTALLATION 14 2 HANDLE COLUMN DISASSEMBLY ASSEMBLY 14 3 I IGNITION COIL AIR GAP CHECK ADJUSTMENT 7 6 IGNITION COIL INSPESTION 7 7 IGNITION COIL REMOVAL INSTALLATION 7 3 IGNITION SYSTEM TROUBLESHOOTING 7 2 L LUBRICATION 3 11 LUBRICATION SEAL PO...

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