EAS00316

BELT DRIVE

V-BELT CASE COVER

BELT DRIVE

ENG %m

%. 10Nm(1.0m • kg, 7.2 ft • lb)

Order

1

2

3

4

5

Job/Part

Removing the V-belt case cover

Kickstarter

Cover

V-belt case cover

V-belt case cover gasket

Dowel pin

P|« 12Nm(1.2m • kg, 8.7 ft* lb)

Q’ty

Remarks

Remove the parts in the order listed.

1

1

1

1

2

For installation, reverse the removal procedure.

5-39

EAS00338

KICKSTARTER

BELT DRIVE

ENG

% m

Order Job/Part

Disassembling the kickstarter

V-belt case cover

1 Kick pinion gear

2 Kick pinion gear clip

3 Circlip/Plate washer

4 Kickstarter shaft

5 Torsion spring

6 Solid bush

Remarks

Q’ty

Remove the parts in the order listed.

Refer to”V-BELT CASE COVER“.

1

1

1/1 Refer to”INSTALLING THE KICKSTARTER”.

1

1

1

For assembly, reverse the disassembly procedure.

5-40

5-41

BELT DRIVE

ENG %m

EAS00340

INSTALLING THE KICKSTARTER

1. Install:

8solid b u s h 1

8kick shaft assembly 2

8torsion spring 3

2. Hook:

8torsion spring

NOTE:

Hook the spring e n d a on the kickstarter shaft b as shown, and hook the other end c on the projectiond .

3. Install:

8plain washer

8circlip 1 N e w

4. Install:

8kick pinion g e a r 1

8kick pinion gear c l i p 2

NOTE:

8 Lubricate the kick pinion gear clip and shaft with molybdenum disulfide oil.

8 Install the kick pinion gear clip at the position shown.

V-BELT AND PRIMARY/SECONDARY SHEAVE

BELT DRIVE

ENG %m

40Nm (4.0 m « kg, 28.9 f H b)

30Nm (3.0 m « kg, 21.7 f H b)

8

9

10

11

12

13

4

5

6

7

Order

1

2

3

Job/Part

Removing the V-belt and primary/secondary sheave

Primary sheave nut/Plate washer

Oneway clutch

Primary fixed sheave

Secondary sheave nut

Clutch housing

Secondary sheave

V-belt

Plate washer

Collar

Primary sliding sheave

Cam/Weight

Slider

Plate washer

Q’ty

Remarks

Remove the parts in the order listed.

1/1

1

1

1

1

1

1/6

3

1

1

1

1

1

Refer to”REMOVING THE PRIMARY

SHEAVE” and “INSTALLING THE SEC-

ONDARY SHEAVE, V-BELT AND PRI-

MARY SHEAVE” .

Refer to”REMOVING THE SECOND-

ARY SHEAVE AND V-BELT” and “IN-

STALLING THE SECONDARY

SHEAVE, V-BELT AND PRIMARY

SHEAVE” .

For installation, reverse the removal procedure.

5-42

SECONDARY SHEAVE

BELT DRIVE

ENG %m

Order Job/Part

Disassembling the secondary

Q’ty sheave

1 Clutch carrier nut

2 Clutch carrier

Remarks

Disassemble the parts in the order listed.

Refer to”DISASSEMBLING THE SEC-

1 ONDARY SHEAVE” and “ASSEMBLING

THE SECONDARY SHEAVE”.

3 Clutch shoe spring

4 Compression spring

5 Secondary spring seat

6 Guide pin

7 Secondary sliding sheave

8 O-ring

9 Oil seal

0 Secondary fixed sheave

3

1

1

2

1

2

2

1

Refer to”ASSEMBLING THE SECOND-

ARY SHEAVE” .

For assembly, reverse the disassembly procedure.

5-43

BELT DRIVE

ENG %m

EAS00317

REMOVING THE PRIMARY SHEAVE

1. Remove:

8primary sheave nut 1

8plate washer

8oneway clutch

8primary fixed sheave 2

NOTE:

While holding the primary fixed sheave with the rotor holding tool 3 , loosen the primary fixed sheave nut.

Rotor holding tool

90890-01235 (YU-01235)

-^— "\f ^^^^\\

Jf2/®

-^z^r^^

«S

If M.

/ / jS/Ki/

EAS00318

REMOVING THE SECONDARY SHEAVE AND

V-BELT

1 . Remove:

8secondary sheave nut 1

8clutch housing 2

NOTE:

While holding the clutch housing with the sheave holder 3 , loosen the secondary sheave nut. y-

Sheave holder

90890-01701 (YS-01880-A)

2. Loosen:

8clutch carrier nut c C

Do not remove the clutch carrier nut at this stage.

NOTE:

While holding the clutch carrier with the rotor holding tool 1 , loosen the clutch carrier nut one full turn with the socket wrench 2 .

5-44 f,

Rotor holding tool

90890-01235

YU-01235

Socket wrench(39mm)

90890-01493

%-©

1 // / /Py*—\ 1

BELT DRIVE

ENG

% m

3. Remove:

8secondary sheave 1

8V-belt 2

NOTE:

Remove the V-belt and secondary sheave from the primary sheave side.

EAS00319

DISASSEMBLING THE SECONDARY

SHEAVE

1. Remove:

8clutch carrier nut 1

NOTE:

Install the clutch spring holder 2 and clutch spring holder arm 3 onto the secondary sheave as shown. Then, compress the spring, and remove the clutch carrier nut 1 .

Clutch spring holder

90890-01337

YM-33285

YM-33285-6

5-45

CHECKING THE CLUTCH SHOES

The following procedure applies to all of the clutch shoes.

1. Check:

• clutch shoe

Damage/wear -» Replace the clutch shoes and springs as a set.

Glazed areas -» Sand with coarse sandpaper.

NOTE:

After sanding the glazed areas, clean the clutch with a cloth.

2. Measure:

• clutch shoe thickness

Out of specification -» Replace the clutch shoes and springs as a set.

j^ia

\1J

BELT DRIVE

Clutch shoe thickness

3.7mm(0.146in)

<Limit>:2.0mm(0.079in)

NOTE:

8 Inspect clutch shoesa.

8 After removing the clutch shoe spring, do not use them again.

8 Replace the all three as a set.

EAS00320

CHECKING THE V-BELT

1. Check:

• V-belt ®

Cracks/damage/wear -» Replace.

Grease/oil -» Clean the primary and secondary sheave.

2. Measure:

• V-belt width a

Out of specification -» Replace.

V-belt width

17.9 mm (0.705 in)

<Limit>: 16.1 mm (0.634 in)

CHECKING THE PRIMARY SHEAVE

1. Check:

• primary sliding sheave ©

• primary fixed sheave ®

Cracks/damage/wear -» Replace the primary sliding sheave, primary fixed sheave and V-belt.

5-46

2. Check:

• free movement

Stick or excessive play -» Replace the primary sliding sheave or collar.

NOTE:

Insert the collar ® into the primary sliding sheave ® , and check for free movement.

BELT DRIVE

ENG

EAS00321

CHECKING THE PRIMARY SHEAVE WEIGHTS

The following procedure applies to all of the primary sheave weights.

1. Check:

• primary sheave weight

Cracks/damage/wear -* Replace.

2. Measure:

• primary sheave weight outside diameter a

Out of specification -* Replace.

Primary sheave weight outside diameter

15 mm (0.591 in)

<Limit>: 14.5 mm (0.571 in)

CHECKING THE SLIDER

1. Check:

• slider ©

Damage/wear^ Replace

EAS00322

CHECKING THE SECONDARY SHEAVE

1. Check:

• secondary fixed sheave

• secondary sliding sheave

Cracks/damage/wear -* Replace the secondary fixed and sliding sheaves as a set.

5-47

2. Check:

• torque cam groove ©

Damage/wear -* Replace the secondary fixed and sliding sheaves as a set.

3. Check:

• guide pin (2)

Damage/wear -* Replace the secondary fixed and sliding sheaves as a set.

5-48

BELT DRIVE

ENG %m

EAS00323

ASSEMBLING THE PRIMARY SHEAVE

1 . Clean:

8primary fixed sheave 1

8primary sliding sheave 2

8collar 3

8primary sheave weights 4

NOTE:

Use thinner to clean up grease, dirt on the primary sliding sheave cam side 5 .

2. Install:

8primary sliding sheave 1

8primary sheave weights 2

8collar 3

3. Install:

8sliders 1

8cam 2

BELT DRIVE

ENG

# 1

1&m\

EAS00324

ASSEMBLING THE SECONDARY SHEAVE

1. Lubricate:

8secondary fixed sheave’s inner surface

1

8secondary sliding sheave’s inner surface

2

8oil seals

8bearings

(with the recommended lubricant)

Recommended lubricant

BEL-RAY assembly lube

®

2. Install:

8secondary sliding sheave 1

NOTE:

Install the secondary sliding sheave onto the secondary fixed sheave 2 with the oil seal guide

3 . m

Oil seal guide

90890-01384 (YM-33299)

5-49

3. Install:

8guide pin 1

4. Lubricate:

8guide pin groove 2

8o-ring New 3

(with the recommended lubricant)

Recommended lubricant

BEL-RAY assembly lube

®

®

©

I f ' / /F^r~\\

BELT DRIVE

ENG

% m

5. Install:

8secondary sheave 1

8spring

8clutch carrier 2

NOTE:

Attach the clutch spring holder 3 and clutch spring holder arm 4 onto the secondary sheave as shown. Then, compress the spring, and tighten the clutch carrier nut 5 .

Clutch spring holder

90890-01337 (YM-33285)

( YM-33285-6)

EAS00325

INSTALLING THE SECONDARY SHEAVE, V-

BELT AND PRIMARY SHEAVE

1. Install:

8V-belt 1

8secondary sheave 2 c C

Do not allow grease to contact the V-belt, secondary sheave assembly.

NOTE:

8 Install the V-belt onto the primary sheave side.

8 Install the V-belt with printed arrow mark on the V-belt facing in the direction shown in the illustration.

5-50

2. Tighten:

8 clutch carrier nut

X I 55Nm(5.5m

* kg, 39.8ft

* lb)

NOTE:

While holding the clutch carrier with the rotor holding tool © , tighten the clutch carrier nut with the socket wrench ® .

5-51

BELT DRIVE

ENG %m

Rotor holding tool

90890-01235

YU-01235

Socket wrench(39mm)

90890-01493

3. Install:

• clutch housing (T)

• secondary sheave nut ®

X I 40Nm(4.0m

* kg, 28.9ft

* lb)

NOTE:

Tighten the secondary sheave nut with the sheave holder ® .

^

Sheave holder

90890-01701

YS-01880-A

4. Install:

• primary fixed sheave ©

• oneway clutch

• plate washer

• primary sheave nut ®

X I 30Nm(3.0m

* kg, 21.7ft

* lb)

NOTE:

While holding the primary fixed sheave with the rotor holding tool ® , tighten the primary fixed sheave nut.

5-52

BELT DRIVE

ENG %m

5. Position:

8V-belt 1

NOTE:

Position the V-belt in the primary sheave 2

(when the pulley is at its widest position) and in the secondary sheave 3 (when the pulley is at its narrowest position), and make sure the Vbelt is tight.