10
41. To remove the rotary valve disc, insert your
finger up through the bottom of the fuel inlet
port and gently dislodge the rotary valve disc
from the crankshaft collar. If a screw driver is
used to assist in removing the disc, use
extreme caution to avoid damaging any part of
the rotary valve cavity. (Fig. 11)
42. Remove the crankshaft collar and locating
pin. The locating pin may be removed with a
needle-nosed pliers.
43. Remove the washer and spring guide from the
kick starter shaft.
44. Unhook the upper spring hook on the kick
starter return spring by striking the upper
end of the spring on the side opposite the
spring hook. This will pop the spring hook
from the hole in the kick starter shaft.
45. Unhook the lower end of the kick starter
return spring from the crankcase and lift off
the spring.
46. Using the circlip expander (special tool)
remove the circlip from the kick starter shaft.
47. Using an open end wrench, remove the shift
drum stopper pivot screw (Fig. 12). Unhook
the shift drum stopper spring and remove the
shift drum stopper. Inspect it for bends of
abnormal wear. The disc on the end of the
shift drum stopper should rotate freely.
48. Lift the shift arm pawl free of the shift
drum and holding it in this position, carefully
withdraw the shift arm and shaft assembly.
Inspect the shift arm assembly for bends,
damage or abnormal wear. Remove the thrust
receiver.
49. Position the engine on the bench with the
magneto side facing upwards and remove the
crankcase retaining screws. It may be
necessary to use an impact driver to remove
these screws as they are inserted very tightly.
The impact driver will enable you to remove
the screws without damaging the screw heads.
See tool list, figure 1. (The drive sprocket
should be removed as soon as the engine is
turned magneto side up.)
50. With all crankcase retaining screws removed,
carefully tap the crankcase with a soft faced
hammer to break the gasket seal and separate
the crankcase halves.
51. Carefully lift out the two transmission shafts
and gears together with the shift drum-shift
fork assembly.
52. Remove the shift drum/shift fork assembly
from the transmission gears and inspect the
shift forks for bends or abnormal wear. (Fig.
13)
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