44
4. If a chain guide is damaged, it must be replaced.
LYC041
5. Inspect timing chain for any abnormality and tooth-
ing.
CYLINDER SLEEVE
Inspecting Cylinder Sleeve in Upper
Crankcase
NOTE: Follow the steps below for measuring cylin-
der sleeve wear when installed in crankcase.
1. Using a micrometer and a snap gauge, measure the
cylinder sleeve diameter in three locations: 1/2”-1”
from top, at the middle and 1/2”-1” from bottom.
Measure again in those three locations at 90° from
the first measurements for a total of six measure-
ments. The trueness (out-of-round) is the difference
between the highest and lowest measurement. Maxi-
mum trueness (out-of-round) must not exceed speci-
fications.
2. If any measurement exceeds the limit, replace the
cylinder and piston.
3. Inspect for longitudinal scratches and if the honing
crosshatch is visible.
4. Replace the sleeve if scratches are present or the
honing structure is worn.
Removing Cylinder Sleeve
1. Mark exact radial position.
2. Tap to evenly dislodge cylinder sleeve from crank-
case and remove out the top. Account for O-ring.
NOTE: Use a drift pin made of solid plastic or hard-
wood. Drive out the sleeve carefully in small steps
around the circumference to avoid tilting.
LYC026
Installing Cylinder Sleeve
1. Grease new O-ring and install on liner.
2. Orientate sleeve in previously marked position and
carefully install in top of upper crankcase.
NOTE: Sleeve must be inserted to align perfectly
straight with the crankcase otherwise serious damage
can occur.
INSPECTING STARTER CLUTCH/GEAR
1. Place the starter clutch gear onto the rotor/flywheel
and attempt to rotate the starter clutch gear clock-
wise. It should lock up to the rotor/flywheel. Rotate
the gear counterclockwise and it should turn freely. If
it moves or locks up both ways, the starter clutch
must be replaced.
LYC042
2. Inspect the starter clutch gear for chipped or missing
teeth or discoloration/scoring of the clutch surface.
Inspect the bearing for loose, worn, or discolored
rollers. If bearing is damaged, it must be replaced.
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