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CHAPTER 18
ENGINE
WORKSHOP MANUAL
TL 250
18.5.27 Inspect the starter motor and step gear.
Check the starter motor's teeth for damage and check the step gear for wear or damage.
18.5.28 Inspect the gearshift
Check the index plate roller for wear or for impeded movement.
18.5.29 Assemble the kickstarter spindle
Insert the kickstarter spindle in the relevant opening in the right side of the engine case. If the motorcycle has an electric starter,
you can skip this step.
18.5.30 Assemble the step gear
Slip the step gear onto the relevant spindle on the right side of the engine case.
Fit the step gear's washer on its outer side.
Insert the circlip in the groove on the step gear shaft.
18.5.31 Assemble the gearshift
Fit the drive shaft, then insert the shift drum and the shift star.
Line up the gap with the drum's pin, insert the fastening screw and tighten it.
Insert the shift lever and adjust the lever if the gear sequence is incorrect. Carry on with assembly if the gear sequence is correct.
18.5.32 Assemble the oil pump on the right side of the engine case
Insert the oil pump pin in the relevant hole in the pump shaft.
Insert the rotor assembly in the opening in the right side of the engine case and secure the oil pump cover plate assembly on the
rotor using the three M5×18 screws.
Install the oil pump rotor with the inner and outer rotors' side with the markings facing in the same direction.
Torque setting: Oil pump cover plate screws: 7 to 9 Nm
While assembling the cover plate, make sure the pump shaft can turn freely.
Fit the oil pump gear assembly on the pump shaft and insert a circlip in the groove in the pump shaft.
Slide the oil pump intermediate gear washer onto the gear shaft before fitting the actual gear. Next, slide the intermediate gear
washer onto the gear before inserting the circlip in the groove in the gear shaft.
18.5.33 Assemble the freewheel
Fit the shim on the freewheel's outer.
During assembly, make sure the shim is positioned correctly.
18.5.34 Install the primary gear and freewheel
Slide the primary gear's washer onto the right end of the crankshaft.
Slide the primary gear and freewheel onto the right end of the crankshaft.
Coat the primary gear's hole with a layer of lubricating grease before installing the primary gear.
Summary of Contents for TL 250
Page 1: ...1 WORKSHOP MANUAL E N...
Page 3: ...WORKSHOP MANUAL TL 250...
Page 11: ...11 WORKSHOP MANUAL TL 250...
Page 30: ...30 WORKSHOP MANUAL TL 250 CHAPTER 6 DASHBOARD 39 GENERAL CONTENT AND CONSULTATION ENGLISH...
Page 49: ...49 49 WORKSHOP MANUAL TL 250...
Page 51: ...51 CHAPTER 15 ELECTRICAL DEVICES 51 WORKSHOP MANUAL TL 250...
Page 136: ...136 136 WORKSHOP MANUAL TL 250...