Replace gears if worn or damaged.
If there are scores or chips on the surfaces of the freewheel gear teeth, check the running surfaces of the flywheel ring gear teeth.
2. Check freewheel. Check that the drive gear rotates clockwise freely and counterclockwise does not rotate.
If conditions are not met, replace freewheel.
3. Replace freewheel (if necessary).
A. Drive side starter cover and freewheel disassembly.
A) Clamp the copper rod in a vise and install the drive side starter cover with freewheel assembly onto it.
b) Click on the drive gear.
V) Using a plastic-faced hammer, knock down the stopper sleeve.
G) Use a screwdriver to pry out the retaining ring.
d) Remove:
- (1) limit bushing,
- (2) drive gear,
- (3) spring.
e) Press the starter cover on the drive side and remove the spring retainer.
and) Disconnect:
- (1) drive side starter cover
- (2) overrunning clutch,
- (3) spring,
- (4) clutch shaft.
If conditions are not met, replace freewheel.
B. Assemble drive side starter cover and overrunning clutch.
A) Connect:
- (1) drive side starter cover
- (2) overrunning clutch,
- (3) spring,
- (4) clutch shaft.
b) Clamp the copper rod in a vise and install the drive side starter cover and freewheel assembly onto it.
V) Press the starter cover on the drive side and install:
- (1) spring holder,
- (2) spring,
- (3) drive gear,
- (4) restrictive bushing.
G) Click on the drive gear.
d) Install a new retaining ring.
e) Using pliers, crimp the retaining ring.
and) Remove the freewheel drive end starter cover assembly from the copper rod.
h) Using a plastic-faced hammer, seat the freewheel shaft in place and install the stopper sleeve onto the retaining ring.