Yamaha WR450Fv2008, Owner'S Service Manual

Page: 138 / 220

5-44
KICK SHAFT AND SHIFT SHAFT
INSTALLING THE SHIFT GUIDE
AND SHIFT LEVER ASSEMBLY
1. Install:
•
Spring "1"
• Pawl pin "2"
•
Pawl "3"
To shift lever "4".
Apply the engine oil on the spring,
pawl pin and pawl.
2. Install:
•
Shift lever assembly "1"
To shift guide "2".
3. Install:
• Shift lever assembly "1"
•
Shift guide "2"
•
The shift lever assembly is installed
at the same time as the shift guide.
•
Apply the engine oil on the bolt
(segment) shaft.
4. Install:
•
Bolt (shift guide) "1"
INSTALLING THE SHIFT SHAFT
1. Install:
•
Roller "1"
• Collar "2"
•
Torsion spring "3"
• Washer "4"
• Shift shaft "5"
Apply the engine oil on the roller and
shift shaft.
2. Install:
• Shift pedal
Refer to "AC MAGNETO AND
STARTER CLUTCH" section.
INSTALLING THE KICK SHAFT
ASSEMBLY
1. Install:
• Kick gear "1"
•
Washer "2"
• Circlip "3"
•
Ratchet wheel "4"
• Spring "5"
•
Washer "6"
• Circlip "7"
To kick shaft "8".
•
Apply the molybdenum disulfide oil
on the inner circumferences of the
kick gear and ratchet wheel.
• Align the punch mark "a" on the
ratchet wheel with the punch mark
"b" on the kick shaft.
2. Install:
•
Torsion spring "1"
To kick shaft "2".
Make sure the stopper "a" of the tor-
sion spring fits into the hole "b" on the
kick shaft.
3. Install:
•
Spring guide "1"
Slide the spring guide into the kick
shaft, make sure the groove "a" in the
spring guide fits on the stopper of the
torsion spring.
4. Install:
• Kick shaft assembly "1"
•
Washer "2"
•
Apply the molybdenum disulfide
grease on the contacting surfaces
of the kick shaft stopper "a" and kick
shaft ratchet wheel guide "3".
•
Apply the engine oil on the kick
shaft.
•
Slide the kick shaft assembly into
the crankcase and make sure the
kick shaft stopper "a" fits into the
kick shaft ratchet wheel guide.
5. Hook:
•
Torsion spring "1"
Turn the torsion spring clockwise and
hook into the proper hole "a" in the
crankcase.
Bolt (shift guide):
10 Nm (1.0 m•kg, 7.2
ft•lb)