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1. Starter crankshaft shim - .007"

2. Starter shaft thrust plate

3. Starter crank gear stop pin washer

Figure 4C-3. Installing Starter Crankshaft

fit in crankcase. Washer is locked in place by peening stop pin end.

ASSEMBLY (Fig. 4C-2)

Install oil seal (13) in left crankcase. Slip thrust washer (15) on starter crankshaft (11), flat side of washer up as positioned on motorcycle. Insert steel shims (14) on crankshaft if needed, as described under "Inspection and Repair," and install crankshaft in left case engaging notched thrust plate (15) with stop pin washer (22) using grease to hold in place (see Fig. 4C-3).

Turn starter crankshaft until notch (A, Fig. 4C-2) is upright as positioned on motorcycle. Place starter crank gear on squared end of shaft, recessed portion of cam plate facing down, end of slot against stop pin as shown in Fig. 4C-4. When positioning crank gear (12) on. shaft (11) be extremely careful that thrust washer does not become dislocated from stop pin washer (see Fig. 4C-3).

Slip lock washer (10) over crankshaft end (11) engaging prong of washer with hole in crank gear face. Install and securely tighten crank nut (9), with flat side of nut against washer.

Slip starter clutch gear (6) over spacer (7), grooved side of gear bushing against lip of spacer collar. Position small end of spring (8) in clutch gear bushing groove.

Press starter clutch gear assembly over clutch gear, compressing spring (8) and at the same time turning starter crank gear to permit meshing of gear teeth.

Return starter crank gear to original position as shown in Fig. 4C-4, with clutch gear held against cam plate by spring tension.

{caution]

If clutch sprocket spacer only (7), is replaced, the new spacer must be exactly the same length as the old spacer. Spacers are available in two lengths, 1.025 and 1.047 in. If starter clutch gear (6), starter clutch (18), clutch sprocket hub or clutch gear are replaced it is absolutely necessary to check the clearance between teeth on starter clutch gear (6) and starter clutch (18) as follows:

1. Measure distance from end of clutch sprocket spacer to top of starter clutch gear teeth.

2. On clutch sprocket assembly, measure distance from top of starter teeth to clutch sprocket thrust washer.

3. Subtract the sprocket reading (2) from the clutch gear reading (1) to obtain clearance.

Figure 4C-4. Positioning Starter Crank Gear on Starter Shaft

4. If resulting clearance is less than .040 in. using short spacer (7), length 1.025 in., install long spacer, length 1.047 in., to obtain .040 in. minimum clearance.

The following alternate method may also be used:

Using a discarded Clutch Sprocket Assembly, Part No. 37701-57, improvise a gauge to measure clearance between clutch teeth on starter gear (6) and clutch (18). Cut a "pie-shaped" section from the clutch shell to permit measurement between teeth with feeler gauge. Temporarily slip improvised clutch shell gauge over clutch gear and hold firmly against spacer (7). With a feeler gauge measure clearance between clutch teeth. If measured clearance is less than .040 in. using short spacer (7), length 1.025 in., install long spacer, length 1.047 in., to obtain .040 in. minimum clearance. See "Transmission Specifications," Section 4A.

Reassemble clutch as described in "Assembling Clutch," Section 4B.

Engage clutch cable end with clutch release lever and install transmission sprocket cover (5) and bolts (4). Install exhaust pipe and muffler.

Slip spring (3) over squared end of shaft (11), end of spring and notch (A, Fig. 4C-2) up as positioned on motorcycle. Using a screwdriver rotate spring clockwise and engage with stud (17). Install bolt, lock washer and nut (1).

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