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Rebuild Tutorial:
Assemble
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
Step 7 (image
7) Tool, size: standard
5mm hex wrench
install clutch cover with gasket install
(10) clutch cover screws
Step 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
Step 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