Table of Contents
1. Kick shaft assembly
2. Spring guide
3. Torsion spring
4. Kick crank assembly
5. Kick lever
)
6. Plug
7. Wave washer
8. Circlip
9. Kick lever cover
10. Hexagon bolt
11. Kick pinion gear
12. Clip
13. Drive gear
14. Oil seal
E. Primary Drive Gear and Clutch As-
sembly
1. Install thej primary drive gear onto the
crankshaft!
Primary drive} gear nut torque:
3.0 m-kg (|22 ft-lb)
1 • Nut
j 5. Thrust plate 1.
2. Plate washer
6. Crankshaft
3. Absorber 2
7. Collar
4. Primary drive gear
8. Absorber 1.
9. Spacer
10. Straight key
2. Install the clutch assembly onto the
main axle.
F. Crankcase Cover (Right)
Install crankcase cover.
G. Piston
1. During reassembly, coat the piston ring
grooves, piston skirt areas, piston pin
and bearing with two-stroke oil.
2. Install new piston pin clips and make
sure they are fully seated in their
grooves.
NOTE:
Take care during installation to avoid damag-
ing the piston skirts against the crankcase as
the cylinder is installed. Note the two induc-
tion holes in the piston skirt. These must be
to the rear during installation.
H. Cylinder
1. Install a new cylinder base gasket.
2. Install cylinder with one hand while
compressing piston rings with other
hand.
NOTE:
Make sure the rings are properly positioned.
I. Cylinder Head
Install cylinder head gasket and cylinder
head.
Cylinder head nut torque:
1.0 m-kg (7.0 ft-lb)
3-12
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