Glenn's Manual

Section 4 - Engine Service   pages 51-111
 

Principles of Operation 53   Overhauling the Engine (cont)  
General Service Instructions 54        Cleaning and Inspecting 66
     Fasteners 54             Cylinder Heads 66
     Ordering Parts 55             Cylinder Bore 67
General Tools 55             Piston and Rings 68
     Feeler Gauges 55             Crankshaft 69
     Compression Gauge 55             Crankcases 70
     Vernier Caliper 55        Assembling the Engine 70
     Micrometer 55             Output Shaft 70
     Torque Wrench 56             Driveshaft 74
     Circlip Pliers 56        Assembling the Crankcase Halves 79
     Metric Sockets 56        Testing the Transmission Shifting 81
     Metric Wrenches 56             First Gear 81
     Voltmeter/Ohmmeter 56             Second Gear 83
Special Tools 56             Third Gear 83
     Impact Screwdriver 56             Fourth Gear 83
     Lock Plate 56             Fifth Gear 84
     Clutch Hub Wrench 56        Engine Assembly continued 85
     Wrist Pin Puller 56             Kickstarter Assembly 85
     Dial Indicator 56        Fitting the Engine to Frame 88
     Continuity Device 56        Assembling RH Side of Engine 89
     Socket Wrench 56             RH Engine Cover - H Series 94
     Spanner Wrenches 56             RH Engine Cover - S Series 95
     Crankcase Leakage Gauge 57        Assembling LH Side of Engine 96
Overhauling the Engine 57        Assembling Top End of Engine 99
     Disassembling 57   Engine Specifications 109

Index

 

 Engine Service 51


 Exploded View 52

 Principles of Operation 53

 General Service Instructions 54

 General Tools 55

 Special Tools 56

 Disassembly 57

58

 Cylinder Removal 59

 Rotor Removal 60

61

 Clutch Removal 62

63

 Splitting Cases 64

65

 Cleaning & Inspection 66

 Cylinder Inspection 67

 Piston Inspection 68

 Crankshaft Inspection 69

 Engine Assembly 70

71

72

73

74

75

76

 Kickstart Assembly 77

78

 Crankcase Assembly 79

80

 Transmission Test 81

82

83

84

 Kickstarter Installation 85

86

87

 Fitting Engine to Frame 88

 RH Side Assembly 89

90

91

 Clutch Assembly 92

93

94

95

 LH Side Assembly 96

97

98

 Top End Assembly 99

100



 Shift Lever Assembly







 Cable Assembly

 Chain Adjustment

 Brake Adjustment

 Engine Specifications 109