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Repair Instructions
WARNING!
Exercise care to ensure the spring
does not fly out and causes personal
injury. Wear protective goggles.
7.4 Replacing a broken return spring
1
Loosen the screw at the center of the starter pul-
ley and the screws on the cassette. Remove the
starter pulley with the cassette and spring. See
Figure 5a.
2
Remove the broken cassette and replace it with a
new one.
3
Tighten the screw at the center of the starter pul-
ley with a tightening torque of 2-2.5 Nm. Load the
return spring, see “Loading the return spring”.
7.5 Assembling the starter unit
1
Fit the starter to the crankcase and tighten the
screws with a tightening torque of 2.5-3.5 Nm.
See Figure 6a.
Check the ignition module as follows:
• Remove the cylinder cover.
• Connect test spark plug 502 71 13-01 to the
ignition cable and clamp the test spark plug
onto the cylinder.
• Turn over the engine with the starter cord.
• If a spark appears on the test spark plug, the
ignition module is not faulty.
Testing the ignition module
In case of malfunctioning ignition system, the
ignition module must be tested before the ignition
system is removed.
Fig 5a
Fig. 6b
Fig 6a
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