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9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER

AGILITY 50

9

5.0

6.0kg-m

3.5-4.5g-m

9
3.5-4.0g-m

9-0

9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER
SERVICE INFORMATION.......................9-1 TROUBLESHOOTING..............................9-1 LEFT CRANKCASE COVER ...................9-2 KICK STARTER ........................................9-2

AGILITY 50

DRIVE BELT .......................................... 9-5 DRIVE PULLEY ..................................... 9-6 CLUTCH/DRIVEN PULLEY ................. 9-9

SERVICE INFORMATION
GENERAL INSTRUCTIONS The drive pulley, clutch and driven pulley can be serviced with the engine installed. Avoid getting grease and oil on the drive belt and pulley faces. Remove any oil or grease from them to minimize the slipping of drive belt and drive pulley. SPECIFICATIONS Item Movable drive face bushing I.D. Drive face collar O.D. Drive belt width Clutch lining thickness Clutch outer I.D. Driven face spring free length Driven face O.D. Movable driven face I.D. Weight roller O.D. TORQUE VALUES Drive face nut Clutch outer nut Clutch drive plate nut SPECIAL TOOLS Universal holder Standard (mm) 23.989~24.025 23.960~23.974 17.5 107.0-107.2 33.965-33.485 34.0-34.025 15.920~16.080 Service Limit (mm) 24.06 23.94 16.5 1.5 107.5 154.6 33.94 34.06 15.4

5.5~6.5kgf-m 3.5~4.5kgf-m 5.0-6.0kg-m

Clutch spring compressor

TROUBLESHOOTING
Engine starts but motorcycle won`t move Worn drive belt Broken ramp plate Worn or damaged clutch lining Broken driven face spring Engine stalls or motorcycle creeps Broken clutch weight spring Lack of power Worn drive belt Weak driven face spring Worn weight roller Fouled drive face

9-1

9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER
LEFT CRANKCASE COVER
REMOVAL Loosen the drive belt air tube band screw. Remove the eight left crankcase cover bolts and left crankcase cover. Remove the seal rubber and dowel pins. Inspect the seal rubber for damage or deterioration. Use specified genuine parts for replacement.

AGILITY 50
Left Crankcase Cover

Air Tube Band Bolts Kick Starter Spindle

KICK STARTER
REMOVAL Remove the kick lever from the kick starter spindle. Remove the circlip and washer from the kick starter spindle.

Washer

Circlip

Gently turn the kick starter spindle to remove the starter driven gear together with the friction spring.

Remove the kick starter spindle and return spring from the left crankcase cover. Remove the kick starter spindle bushings.

Friction Spring

Starter Driven Gear Kick Starter Spindle

Return Spring

9-2

9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER
Spindle

AGILITY 50
Return Spring

INSPECTION Inspect the kick starter spindle and gear for wear or damage. Inspect the return spring for weakness or damage. Inspect the kick starter spindle bushings for wear or damage.

Plastic Bushing Spindle Bushing Friction Spring

Inspect the starter driven gear for wear or damage. Inspect the friction spring for wear or damage.

Starter Driven Gear Kick Starter Spindle Forcing Part

Inspect the kick starter spindle and starter driven gear forcing parts for wear or damage.

Starter Driven Gear Shaft Forcing Part Kick Starter Spindle

INSTALLATION Install the kick starter spindle bushings and return spring onto the left crankcase cover.

Return Spring

9-3

9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER
Install the starter driven gear and friction spring onto the left crankcase cover as the figure shown.

AGILITY 50
Friction Spring

Starter Driven Gear

First install the washer and then install the circlip. Install the kick lever.

Washer Dowel Pins

Circlip

LEFT CRANKCASE COVER INSTALLATION
First install the dowel pins. Install the seal rubber.

Seal Rubber

Install the left crankcase cover and tighten the eight left crankcase cover bolts diagonally. Connect the drive belt air tube and tighten the tube band screw. Install the rear brake cable clamp.

Left Crankcase Cover

Rear Brake Cable Clamp

9-4

9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER
DRIVE BELT
REMOVAL Remove the left crankcase cover. INSPECTION Check the drive belt for cracks, separation or abnormal or excessive wear. Measure the drive belt width. Service Limit: 16.5mm

AGILITY 50

REPLACEMENT Remove the eight left crankcase cover bolts and left crankcase cover. ( 9-2) Hold the clutch outer with an universal holder and remove the clutch outer nut.
Special

Clutch Outer

Nut

Universal Holder

Universal Holder Drive Pulley Face

Hold the drive pulley using a holder and remove the drive face nut, starting ratchet and washer. Remove the drive pulley face.

Drive Face Nut Clutch/Driven Pulley

Remove the drive belt from the clutch/driven pulley.

9-5

9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER
INSTALLATION Turn the driven pulley clockwise to widen the drive belt groove and lay a new drive belt on the driven pulley.

AGILITY 50

Drive Belt Drive Face Nut Drive Pulley Face Drive Belt

Set the drive belt on the drive pulley face collar. Install the drive pulley face, starting ratchet washer. Install and tighten the drive face nut. When installing, align the tooth space of the drive pulley face and starting ratchet with the crankshaft tooth and then tighten the nut.
Starting Ratchet Drive Pulley Face 10mmWasher Starting Ratchet

DRIVE PULLEY
REMOVAL Hold the drive pulley using a holder and remove the drive face nut, starting ratchet and washer. Remove the drive pulley face.

Drive Face Nut (10mm) Movable Drive Face Assembly

DISASSEMBLY Remove the movable drive face assembly and drive pulley collar from the crankshaft.

Drive Pulley Collar

9-6