12
II. REASSEMBLY
All parts installed inside the two crankcase
halves are installed into the magneto clutch
section.
1. Install the kick starter shaft and gear
assembly. Position the pin on the ratchet arm
into the boss provided for it in the crankcase
half.
2. Oil the kick idler gear assembly thoroughly.
This gear need not be removed from the
transmission case during disassembly as it is
pressed into the counter shaft (clutch shaft)
bearing. It is very unlikely that this gear will
ever be replaced during the life of the engine.
3. Reinstall the kick starter intermediate gear
positioning the spacers above and below the
gear. These spacers are identical and can be
identified since the hole in the spacer is the
same size as the hole in the gear. Place it in
mesh with the kick idler gear and the kick
starter shaft gear and oil the gears. (Fig. 15)
4. We are now ready to install the transmission
shaft assemblies and the shift drum/shift fork
assembly. Before doing so, familiarize yourself
with the positions into which the various
shafts and the shift drum will be inserted by
studying figure 15.
• The splined end of the countershaft (the shaft
with the smaller gears) will be inserted
through the kick idler gear, the gear that is
pressed into the countershaft bearing.
• The end of the drive shaft will be inserted into
the kick starter intermediate gear, the one
which was installed with the spacers above
and below it. The splined end of the shaft will
point up and the small sprocket will be
attached to it when the crankcase sections are
joined. The large diameter end of the shift
drum will be inserted into the large hole in the
casting located directly above the kick idler
gear and the kick starter intermediate gear.
5. Align the countershaft and drive shaft gears so
that all gears are in mesh. Plan your
installation of the shafts so that the longer end
of the countershaft extends through the
bottom of the crankcase section. Now insert
the shift forks into the slots of the sliding
gears of the transmission.
6. Holding both shafts and shift drum together as
a unit, install the transmission assembly into
the crankcase half. When the shafts have been
partially inserted, rotate them slightly to mesh
all gears and properly position the shafts.
7. Install the two remaining spacers, one on the
end of the countershaft and the other on the
end of the kick starter shaft.
8. Be certain that the crankshaft end play shims
are positioned on both sides of the crankshaft
balance and install the crankshaft. See figure
16. If a new crankshaft has been installed, it
will be necessary to put the crankcase gasket
into position, install the other crankcase
section and insert several of the crankcase
retaining screws tightly. The crankshaft
should now be checked for end play. If there is
more than .010" to .015" of end play, additional
shims must be added to the crankshaft.
9. Install a new crankcase gasket locating it on
the steel positioning pins. Install the second
crankcase section. Again check transmission
shaft rotation to be certain that the shafts turn
freely. If found to be ok., reinstall the
crankcase retaining screws and tighten them
securely.
10. Trim the excess portion of the crankcase
gasket flush with the cylinder seat.
11. Install the spacer on the shift arm shaft and
position the shift arm shaft assembly into the
crankcase. (Fig. 17)
12. Insert the shift arm pawl into the shift drum
assembly. Install the thrust receiver and bend
the tabs on the tab washer against the flats of
the bolts when the mounting bolts have been
secured. This tab washer prevents the bolts
from loosening during engine operation. (Fig.
12.)
13. Install the shift drum stopper, collar and
retaining screw. Connect the drum stopper
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