450ATV-2 Maintenance Manual _engine
Contents
1. Service Limit 0 100 mm D of Piston hole for Pin Clean Piston hole for Pin Measure ID in the up and down direction and the right angle direction with dial caliper gauge ID of Piston hole for Pin Standard 23 001 to 23 007 mm Piston Pin OD Check for ware and damage on the sliding surface Measure OD at total 3 positions both ends and middle position in the X and Y direction Piston Pin OD 22 996 to 23 000 mm Standard CONNECTING ROD Small end ID Check for ware and damage on the sliding surface Measure ID in the X and Y direction with caliper dial gauge Small end ID 23 007 to 23 020 mm Standard Clearance between small end ID and Piston Pin OD Clearance is small end ID minus Piston Pin OD Clearance between small end ID and Piston Pin OD 11 PISTON RINGS Clearance between Piston Ring and groove Remove carbon deposits from Rings and grooves Measure the clearance between Piston Ring and groove by holding the Ring upwards in the groove with thickness gauge Service Limit of clearance between Piston Ring and groove Piston Ring gap Opening Insert Piston Ring into the lower portion of Cylinder horizontally by using Piston Measure the Piston Ring gap opening with thickness gauge service Limit of Piston Ring gap Opening Oil ring side rail 1 0 mm CRANKSHAFT Runout Seton the V block and measure runout with dial gauge Crankshaft Runout S2. Cylinder Head Cylinder Head warpage Inner diameter ID of Valve Guide Clean up the Valve Guide hole Measure ID of Valve Guide at total 6 points upper middle and bottom positions and X and Y directions by means of dial caliper Service Limit of Valve Guide ID 6 000 to 6 012 mm 6 000 to 6 012 mm INTAKE and EXHAUST VALVE Valve Stem runout Remove carbon deposits Place on the V block Measure the marginal width of valve face portion If the result is out of specifications replace with new valve Valve Stem runout Outer diameter OD of Valve Stem Meastre OD of Valve Stem sliding portion at total 6 points middle and lower positions and X and Y directions by means of micrometer Service Limit of Valve Guide OD 9 945 to 5 960 mm Clearance between Valve stem and Guide Service Limit of Clearance Width of Valve face Measure the marginal width of valve face portion If the result is out of specifications replace with new valve Service Limit of marginal width Valve Spring free length Measure the free length of inner and outer Valve Spring If the result is out of specifications replace with Spring as a set service Limit of free length IN ee ee CAMSHAFT Cam profilw height Check for damage and ware on cam profile portion Measure the height of cam profile Oil clearance at cam journal portion Measure the ID of cam journal port
3. Note Keep Adjusting Pad and Valve Lifter fitting in the Fit two pipe knocks and Head Gasket 23 Install Cylinder Head Apply oil to M11 bolts threads and washer and then tighten them in the following procedure 1 Tighten to 30 N m 2 Tighten to 70 N m 3 Loosen by 180 degrees 4 Loosen by 180 degrees 5 Tighten to 35 N m 6 Turn by 80 to 90 degrees clockwise 7 Turn by additional 80 to 90 degrees clockwise i SNr N N N NSN Fastener M6 X 25L 2 pcs Tighten M6 bolts Tightening Torque 9 11 N m Fastener M6 X 40L 4 pcs Install Chain Lever with pivot bolt Tightening Torque 13 5 16 5 N m Fastener M8 X 22 5L Pivot bolt 1 pcs Put Timing Chain from the Cylinder Head side and set in position as shown in Attachment 2 Fit Crank Sprocket with the chamfer portion inside and with each spline aligned 24 Align the markings between Crank Sprocket and marking pale of Chain Apply oil to Camshafts attaching portion and install Camshaft IN and EX with Cam Sprocket marking and marking plate of Timing Chain aligned Note Decompression is furnished on Camshaft EX Do not mixed up Fit Bearing Stopper onto Ball Bearing Apply oil to Cam Support and install in position Tightening Torque 9 11 N m Fastener M6 X 40L 8 pcs Depress Chain Tensioner plunger into the bottom possition by Special Tool Chain Tensioner Tool And then Install Ten
4. Crank Sprocket by holding the chain at the upper portion cylinder head side Take out Timing Chain MAGNETO ASSY Remove flange nut Take out Magneto Assy along with Starter Gear Needle Bearing and Spacer by means of Special Tool MAG Remover THERMOSTAT Remove bolts and take out Thermostat Cover and Thermostat WATER PUMP Remove bolts and take out Water Pump Case Note Adopt tray to prevent coolant pollution Make sure the original one position of a cupper washer Take out Impeller Take out Sealing Washer Note When reassembling replace with new Sealing Washer CYLINDER HEAD Remove two 2 M6 bolts Remove four 4 M11 bolts evenly and diagonally Lever CP Remove pivot bolt and take out Lever CP Take out Cylinder and Gasket Note Hold Piston not to damage it PISTON Take out Clip and pull out Piston Pin and then take out Piston Remove Starter Motor CRANKCASE Remove bolt on the clutch side Remove bolts on the MAG side Take out the crankcase from Special Tool Engine Base Plate AY and set it with the clutch side facing up on the plastic containers Attach the Special Tool Case Separator Kit onto the clutch cover mating surface of the crankcase Tighten two 2 bolts evenly keeping the opening between mating surfaces of crankcase in the parallel condition TRANSMISSION Take out Fork Shafts Pull out Sp
5. G Cover Set the harness grommet into the groove Fit Gasket MAG Cover onto Crankcase after spot applying TB 1215 onto the Crankcase surface Fit MAG Cover and tighten bolts Tightening Torque 9 11 N m Fastener M6 X 35L 11 pcs Fit Oil Delivery Pipe Tightening Torque 15 21 N m Note Fit gasket on both sides of banjo fitting Set the rubber pipe in horizontal direction 30 Make sure O ring Head Cover and Chain Guide 2 are furnished and fit Head Cover Fit rubb mount and tighten bolts Tightening Torque 9 11 N m Install Adapter with convex portion upwards Tightening Torque 16 20 N m Fastener M8 X 20L 2pcs Install carburetor onto Adapter set Adapter band screw with the screw head upwards on MAG side Tightening Torque M4 X3OL 1pc Fit Shift Pedal with the marking aligned Tightening Torque 9 11 N m Fastener M6X 25L 1pc Apply grease onto front and rear surfaces of Sprocket 14T and install it in position Apply grease to Counter ShaftJ sprocket and install Ficing Plate over the sprocket Tightening Torque 9 11 N m Fastener M6X 12L 2 pcs 31
6. SERVICE MANUAL Manuscript for EW45 Page A Removal and Installation 1 B Disassembly 1 C Inspection 6 D Reassembly 14 Attachment 1 Special Tool 2 Timing Chain 3 Matrix Table 4 Fasteners and Tightening Torque table 5 Tightening Torque chart 6 Service Data 7 Adhesive Sealant and Oil application 8 Periodic Maintenance Schedule 9 Specifications A Removal and Installation Dinli to complete the section pertaining to the engine removal and the installation onto vehicle B Disassembly Set the engine assembly onto Special Tool Engine Base Plate AY Take out Cover CP Drive Chain and Plate Drive Chain Dinli to make Arrangements for Operate Shift Pedal to engage the transmission gears The applicable photo Remove bolts and take out Fixing Plate and then remove Sprocket 14T Remove Shift Pedal Remove Reverse Arm Lever Reverse Lock Remove Carburetor Remove upper side banjo bolt oil fitting first after that other bolts and then take out Oil Delivery Pipe Assy Note Pay attention not to lose total 6 cupper washer MAG Cover CP Note Adopt tray or clothes waste to prevent oil pollution Remove Reduction Gear 1 Shaft 1 Reduction Gear 2 Shaft 2 Make sure their original positions for reassembling Remove Oil Filter Cover and take out Oil Filter CP O ring and Spring Filter Note Adopt tray or clothes waste to prevent oil pollution Rem
7. cing the ID marking M upwards into the groove of Main Shaft Install Shifter Fork Right facing the ID marking R upwards into the upper groove of Counter Shaft Install Shifter Fork left facing the ID marking L upwards into the lower groove of Counter Shaft Install Shift Drum CP in the pin side upright condition Set each pin of Shift Forks into applicable Groove of Shift Drum Insert Spring Fork Shaft into the hole Inner diameter 11 mm each of Shift Fork Right and Left Insert Fork Shaft into Shift Fork Right and Left Insert Fork Shaft into Shift Fork Main Apply oil into the grooves of Fork Shaft and Shift Drum Turn Main Shaft and make sure that Counter Shaft Shift Drum and Shift Fork can be smoothly operated CRANKCASE 2 When replacing Bearing with new one Install Bearing Retainer Plates Stopper Plate for Main Shaft Bearing Tightening Torque 12 14 N m Fastener M6 Hex bolt 1 pcs Stopper Plate B for Shift Drum Bearing Tightening Torque 7 9 N m Fastener M6 Hex bolt 1 pcs Apply TB 1316 to threads Install Drain Plug Tightening Torque 7 9 N m Fastener M16 Bolt 1 pcs Fit Oil Strainer UN On plastic containers place Crankcase 2 with the mating surface to crankcase 1 upwards Apply TB 1215 evenly onto the mating surface Adjust the convex position on the end surface of Water Pump Shaft to meet with the gro
8. ervice Limit 0 06 mm Side clearance at large end of Connecting Rod Measure the side clearance at large end of Connecting Rod with thickness gauge Side clearance at large end Service Limit 0 65 mm TIMING CHAIN Chain Pitch Check for ware damage and roller fallout Place Chain on the flat table and pull with the 4 53 kg force and then measure the length of 20 pitches Timing Chain Pitch 20 pitches STARTER GEAR ONE WAY CLUTCH Disassembly Remove One way Clutch from Flywheel Assy Fastener M6 X 16L Bolt socket head 8 pcs CLUTCH Visual checking Plate and Disk Check for ware and damage Check for movement of bearing If any damage or excessive ware would be found replace with new one as a set Visual checking Release shaft and Push rod Check for ware and damage Width of friction material Measure the width of friction material with caliper gauge Width of friction materal Note Clutch Disk A and B are available Clutch Disk B should be facing front side 13 TRANSMISSION Visual checking Shift Fork and Drum Check for ware and damage If any ware on the Fork craw portion replace with new one Visual checking Main Shaft and Counter Shaft Assy After disassembling check for ware and damage on dug clutch portion gears and spline portions If any ware and damage replace with new one Width of Shift Fork groove Check for ware and scratc
9. h in the Fork groove Measure the width of Shift Fork groove with caliper gauge Width of Shift Fork groove Standard 5 10 to 5 17 mm Width of Shift Fork craw Measure the width of Shift Fork craw with micrometer Width of Shift Fork craw Standard 4 93 to 5 00 mm Clearance between Shift Fork and groove Measure the clearance between Shift Fork and transmission gear groove at craw portion With thickness gauge D Reassembly CRANKCASE 1 Press fit crankshaft into crankcase 1 by means of Special Tool CRANK ASSY TOOL KIT Note Hold Connecting Rod not to strike the Crankcase mating surface while press fitting Install 1 8 plug in position Tightening Torque 9 15 N m Attach Reverse Arm CP onto Crankcase 1 Retain the Reverse Arm CP with washer and snap ring from the outside of Crankcase 1 Note Be sure not to damage oil seal Make sure the snap ring is in the groove without fail On plastic containers place Crankcase 1 with the mating surface upwards Install Balancer Shaft with the markings between Drive Gear of Crankshaft and Driven Gear of Balancer Shaft aligned Install Reverse Shaft CP Install Main Shaft Assy and Counter Shaft Assy with gears engaged into Crankcase 1 Note Pay attention not to miss washer fitting to Counter Shaft Be sure not to damage the lip portion of oil seal by the Counter Shaft end spline Install Shifter Fork Main fa
10. ion with Cam Support fixed to the specified tightening torque 9 11 N m ID of cam journal portion Standard 25 000 to 25 021 mm Measure the OD of Camshaft journal portion with micrometer OD of Camshaft journal portion Standard 24 964 to 24 963 mm Oil clearance is ID minus OD Oil clearance at cam journal portion Service Limit 0 10 mm Viaual Checking Check for ware and damage on Cam Sprocket gear teeth Check for ware and damage on decompression related parts Check if decompression would be operated smoothly If any parts would be damaged or worn replace with new Camshaft Assy CYLINDER Cylinder warpage Clean and remove carbon deposits from the surface Never damage the surface when cleaning Place the measuring block diagonally on the surface and check with thickness gauge Cylinder warpage Cylinder bore Check for damage or ware on bore surface Measure the cylinder bore at total 6 positions top middle and bottom positions and axial Camshaft and right angle directions Cylinder bore PISTON and PISTON PIN Piston OD Check for ware and damage on the sliding surface Measure OD of Piston at 11 mm distance from the bottom end in the right angle against Piston Pin with micrometer Piston OD Standard 93 955 to 93 970 mm Clearance between Piston and Cylinder Clearance is Cylinder ID minus Piston OD Clearance between Piston and Cylinder
11. it Spring Clutch and tighten bolts evenly Tightening Torque 9 11 N m Fastener M6 X 36L 6 pcs Make sure again the tightening torque of Primary Gear fixing nut Tightening Torque 110 130 N m 28 Install Clutch Cover Fit Spring Filter Fit Filter Cover along with Oil Filter CP and O ring Tightening Torque 9 11 N m Fastener M6 X 25L 2 pcs Fit Gasket Clutch Cover onto Crankcase after spot applying TB 1215 onto the Crankcase surface Fit Clutch Cover and tighten bolts Tightening Torque 9 11 N m Fastener M6 X 25L 11 pcs M6 X 65L 1 pc Commonly tighten Filter Cover Tighten Filter Cover plug to the specified tightening torque Install Thermostat with the hole upward and Thermostat Coverl Tightening Torque 7 9 N m Fastener M6 X 20L 2 pcs Install Thermo Switch with the TB 1344 applied to threads Tightening Torque 32 38 N m Install Spark Plug Tightening Torque 15 20 N m 29 Install MAG Cover Apply grease around Shaft 1 and 2 and fit Reduction Gear 1 and 2 in position correspondingly Apply grease to gears Fit Stator Coil into MAG Cover Tightening Torque 5 5 6 5 N m Fastener M5 X 30L 3 pcs Route the coil wiring along the groove and fix Pulsar Coil over the wiring Fit Plug 1 and 2 MAG Cover Tightening Torque Plug 1 10 12 N m Plug 2 3 5 N m Note Make sure O ring is attached onto Plug MA
12. it new clip into the groove on anther side and make sure the clip fitting properly in the groove Apply oil around Piston and Rings and cylinder bore Install Cylinder by holding Rings by Special Tool Ring Band Make sure of the smooth operation by turning Crankshaft with Cylinder pressed down by hand 22 Install Chain Guide 1 onto Cylinder Assemble Cylinder Head as shown in the illustration 1 Seal valve 4 pcs 2 Intake Valve 2 PCS 3 Exhaust Valve 2 pcs 4 Valve Spring Inner 4 pcs 5 Valve Spring Outer 4 pcs 6 Spring Retainer 4 pcs 7 Colette Valve 8 pcs 8 Seat Valve Spring 4 pcs Press fit Seal Valve by means of exclusive tool Note Pay attention on the Seal Valve appearance Intake IN side Black Exhaust EX side Green Fit Seat Valve Spring not to over ride the step Set Valve Spring Inner facing the green paint marking upwards Set Valve Spring Outer facing the yellow paint marking upwards Apply oil onto the shaft ends of IN and EX Valve Valve Guide and Seal Valve and fit the valves into Cylinder Head Note Keep the IN and EX valve fitting in the original position Do not mix IN and EX valves While depressing Valve Springs with exclusive tool fit Soring Retainer and Colette onto valve shaft end Note Make sure of Colette fitting securely to Valve Retainer Do not depress Valve Spring extremely Fit Adjusting Pad and Valve Lifter
13. locator pin of Shift Drum at the groove of Shift Cam and assemble Fix with Shifter Pin Tightening Torque 20 26 N m Note When re using Shifter Pin apply TB 1316 to threads Adhesive LockTite is applied onto new Shifter Pin threads Apply TB 1316 to M6 Stepped bolt threads and fix Stopper Arm CP and Spring Stopper with M6 Stepped bolt Tightening Torque 9 11N m Fastener M6 Stepped bolt 1 pc Note Make sure the Spring Stopper orientation Assembly Oil Pump Assy as shown in the illustration in advance 2 3 4 Oil Pump Case 1 Oil Pump Case 2 Inner Rotor Feed Outer Rotor Feed Inner Rotor Scavenge Outer Rotor Scavenge Oil Pump Shaft Dowel Pin 2 pcs 6 7 8 Ce A A A M AMA a a A ees N N N N N N NN Insert shorter pin 3 X 15L into the hole of Oil Pump Shaft and then assemble with Inner Rotor Scavenge Set Pump Case 1 into Oil Pump Shaft Insert another shorter pin 3 X 15L into the hole of Oil Pump Shaft Assemble Outer Rotor Feed and Inner Rotor Feed with Pump Case 2 and apply oil into rotor Set Oil Pump Shaft into Pump Case 2 fix Case 1 and 2 with two longer pins 3 X 19 8L Fit Outer Rotor Scavenge Install Oil Pump Assy Tightening Torque 9 11 N m Fastener M6 X 30L 3 pcs Note Make sure the smooth rotation of Oil Pump shaft 20 Assemble Drum Shifter and related parts Make sure the spring force and smooth operati
14. on by moving the ratchet pole with finger Install Drum Shifter along with Shifter Collar and Guide Plate onto Shift Cam Tightening Torque 9 11 N m Fastener M6 X 20L 2 pcs Fit Oil Pump Gear and adopt snap ring into the groove on Oil Pump Shaft end Insert Shift Shaft CP with Special Tool Oil Seal Guide adopted Apply oil to Special Tool Oil Seal Guide in advance Engage Stopper Pin and Shifter Collar into the groove of Shifter Lever Note Be sure to fit washer onto Shift Shaft Take out Special Tool Oil Seal Guide temporally fit Shift Pedal CP and make sure gear is shifted properly Also make sure reverse locking operation 21 Apply oil to O ring and install Starter Motor in position Tightening Torque 9 11 N m Fastener M6 X 25L 2 pcs Fit two Pipe Knocks and set Cylinder Gasker Assemble and install Piston Set Piston Rings into Piston grooves Expander Ring into Oil Ring groove Second Ring facing the marking upwards Top Ring facing the marking upwards Make sure rings are smoothly moved and adjust the openings gaps at 120 degrees intervals Fit new clip into the groove on one side and make sure of the clip fitting properly in the groove Place Special Tool Piston Support Plate Insert Piston with the marking on the top surface faced to magneto side into cylinder Apply oil to small end hole of Connection Rod Piston Pin and hole Then fit Piston Pin into Piston F
15. ove Clutch Cover CP Note Adopt tray or clothes waste to prevent oil pollution Clutch Remove bolts and take out Spring and Washer Take out Disk Clutch Pressure Take out Pusher Remove Push Rod by depressing Release Lever Remove Lock Nut Note Lock Nut was caulked and so unlock the caulk by using drill Take out Lock Washer Take out Clutch Distance Collar and Thrust Washer Oil Pump Take out Snap Ring and Oil Pump Gear Remove bolts and take out Oil Pump Case Take out Oil Pump feed Pump Scavenging Pump and Oil Pump Shaft etc Take out Shift Shaft CP along with washer Note Fit the washer onto the Shaft not to lose it GUIDE PLATE DRUM SHJIFTER and SHIFT CAM Remove Guide Plate Drum Shifter and Shift Cam Remove Guide Plate and Drum Shifter Note Pay attention Drum Shifter is not Take out Shifter Pin and then pull out Shifter Cam Remove Stopper Arm and Spring Stopper Take out Point Neutral along with Spring Point and then remove Switch Position Remove nut and take out washer and Primary Gear HEAD COVER Remove bolts and take out Rubber Mounts O ring and Head Cover CHAIN TENSIONER Align the TDC and remove adjusting bolt Remove bolts and tale out Tensioner CAM SUPPORT CAMSHAFTS Remove bolts and take out Cam Support Tank out intake Camshaft exhaust Camshaft and Bearing Stoppers Note Pay attention not to lose Bearing Stoppers Take out
16. ove on the end surface of Balancer Shaft on Crankcase 1 side Cover Crankcase 2 over Crankcase 1 assemble cases by lightly and carefully tapping with hummer to fit mating surfaces properly without decline Note Hold Connecting Rod to keep the position of the groove on the end surface of Balancer Shaft Tighten bolts to the specified tightening torque Tightening Torque 9 11 N m Fastener Case 1 side M6X40L 7 pcs M6X75L 7 pcs M6X50L 1pc Case 2 M6X75L 1 pc Note After tightening all bolts securely make sure Crankshaft is smoothly rotated Install Position Switch Caution Install Position Switch after assembling Crankcase 1 and 2 without fail lf the switch is installed onto Crankcase in advance it will be depressed by shift Drum and damaged when assembling Insert Spring Point into the hole on the end surface of Shift Drum Then insert Point Neutral Apply oil onto O ring of Position Switch and set the switch Tightening Torque 3 5 N m Fastener M5 X 20L 2 pcs Sei the case assembly onto Special Tool Engine Base Plate AY Apply TB 1344 to Reverse Arm Lever threads M6 and install along with Reverse Arm Spring Tightening Torque 9 11 N m Fastener M8 X 12L 1 pc Note Make sure the Reverse Arm Spring orientation Apply TB 1316 to Stopper Pin threads and tighten to the specified tightening torque Tightening Torque 20 26 N m Align the
17. ring located under the Fork Shaft on the counter shaft side Take out Shift Fork Main Shift Fork Right and Shift Fork Left Note Make sure their original positions for reassembling Take out Shift Drum CP with the Reverse Lock released With the case put un the upright position take out Main Shat and Counter Shaft With the case put in the original position again take out Reverse Shaft CP Reverse Idle Gear collar Washer etc Note Pay attention not to lose the Counter Shaft washer BALANCER GEAR Align the mating markings Take out Balancer Shaft and Gear by lightly tapping with plastic hammer CRANKSHAFT Depress the MAG side end of the Crankshaft by means of hand press machine and take out Crankshaft C Inspection CYLINDER HEAD Disassembling Note Identify the original position of disassembled parts with marking as necessary Place them in order on the clean table Remove Valve lifter and adjusting pad While depressing Valve Spring with exclusive too Valve spring compressor take out Colette Take out Spring Retainer Spring inner and outer Seat Spring Take out IN and EX Valve Take out Valve Seal Cylinder Head warpage Clean and remove carbon deposits from the surface Never damage the surface when cleaning Place the measuring block diagonally on the surface and check with thickness gauge If the result is out of specifications replace with new
18. sioner Tightening Torque 9 11 N m Fastener M6 X 25L 2 pcs 25 Take out Special Tool and install bolt with Gasket Aluminum Tightening Torque 4 5 6 N m Fastener M6 X 8L 1 pcs Make sure of smooth operation by turning Crankshaft Adjust valve clearance with thickn gauge adopted at TDC position in the following procedures Valve Clearance Cold condition IN 0 15 0 05 mm EX 0 27 0 05 mm Temporally fit original Adjusting Pad and check the valve clearance results and listed figures 3 digits Select applicable Adjusting Pad and fit it in place with original one Check again valve clearance and make sure it is within the specifications If out of the specifications repeat the procedures Fit One way Valve Tightening Torque 15 21 N m Note Make sure One way Valve Assy is placed in position and then fix plug Install Water Pump Fic Impeller along with Seal Washer by means of Special Tool Wrench Counter Shaft adopted to Counter Shaft Tightening Torque 9 11 N m Fit Case along with Gasket Tightening Torque 9 11 N m Fastener M6 X 25L 7 pcs Note At the bottom one position fit the cupper gasket without fail 26 Install Flywheel Fit Spacer with the chafer side inside onto Crankshaft on the MAG side Apply TB 1306 and remove oil from the taper portion of Crankshaft Fit Needle Bearing and apply grease Not to apply grease onto the taper porion Install One wa
19. y Clutch onto Flywheel Tightening Torque 13 15 N m Fastener M6 X 16L Adhesive LockTite applied bolt 7 pcs Fit Starter Gear and make sure of smooth counterclockwise rotation Apply TB 1306 and remove oil from taper hole of Flywheel Fit Flywheel apply oil to threads and retaining surface of M14 nut Tighten the nut to the specified tightening torque with Special Tool Wrench Crank Sprocket Adopted to Crankshaft for preventing rotation Tightening Torque 150 117 N m Fastener M14 Nut Install Primary Gear with the inside marking aligned to spline Tightening Torque 9 11 N m Fastener M6 X 25L 7 pcs Fit Release Shaft along with Spring Release and Plate Release in position Tightening Torque 9 11 N m Fastener M6 X 20L 1 pcs 21 Install Clutch Assy Assemble Clutch Assy properly after checking disassembled parts Fit Distance Collar into Main Shaft apply oil into hole and turn Collar by one turn Fit Cultch Outer CP lock washer with the hollow surface inwards and lock nut Tightening Torque 90 110 N m Fastener M18 Special nut Caulk the lock nut with Special Tool Caulking Tool Apply oil onto Push Rod and insert into Main Shaft and then fit Pusher Fit Disk Clutch and Plate Clutch Note Make sure the widest friction plate is in the bottom position Set the top plate into the shallow depth groove of Clutch Outer CP Fit Disk Clutch Pressure F
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