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Removing gears
a) Removing driving gear (28 teeth) from output
shaft
— see Fig. 14.
b) Removing coaster pinion — see Fig. 15.
c) Removing driven gear — see Fig. 16.
Removing driver assembly
a) Using a screwdriver, loosen the circlip and
pull the
washer, the volute spring and the complete driver off the
output shaft (Fig. 17)
b) Using circlip pliers, loosen the circlip and
pull the
washer, the cap, and the sprocket off
the shaft (Fig. 18).
c) After loosening the circlip, press the output
shaft out
of the case.
When reassembling the output shaft, use the
sealing
ring installer (Fig. 19) to protect the shaft
sealing rings
from damage,
Removing alternator
a) Use a screwdriver to loosen the alternator
cover
retaining spring, and remove the cover
Then unscrew
the M5 x 25 screw holding down the rotor.
b) Using the rotor drag No. 928-6000-1.1 pull of
the
rotor (Fig. 20) and the loosen the lock pin.
c) Remove two M4 x 22 screws fastening the
stator, and
pull the stator out of the crankcase right-hand half
together with the leads.
After having removed the transmission clutch and the
alternator, use a hand press to press the crankshaft out
of the crankcase.
Engine re-assembly
To re-assemble the engine, reverse the procedure for its
dismantling
a) Warm up the right-hand of the crankcase
to about 70
to 80 °C and press in the crankshaft
b) Reassemble and reinstall the transmission,
c) Press on the left-hand half of the crankcase.
(warmed
up to about 70 to 80°C)
d) Reassemble and reinstall the clutch.
e) Reinstall the reassembled alternator and the
assembled driver (engine drive engaging and
disengaging device)
f) Reinstall the piston, the cylinder, and the cylinder
head.
(The arrow on the piston crown points down, towards
the exhaust port.)
If any of the parts are worn beyond the acceptable
measure, replace them with new ones.
ZVL model 210 Workshop Manual Page 13
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