15.36B ... And turn the shaft to align the pushrod seat (arrowed)

cable through the bracket and into the release lever (see Section 14). Adjust the clutch cable (see Chapter 1). 40 Refill the engine with oil (see Chapter 1).

16 Timing rotor, primary drive gear and balancer gear - removal, jK inspection and installation jQ

Note: This procedure can be carried out with the engine in the frame. If the engine has been removed, ignore the steps which do not apply.

Removal

1. Unscrew the timing inspection plug and the centre plug from the engine left-hand cover. Turn the crankshaft anticlockwise until the line next to the T mark on the alternator rotor aligns with notches in the timing inspection hole (see Section 9). If the engine cover has been removed, align the T mark with the arrow on the crankcase

2. Remove the engine right-hand cover (see Section 15). The primary drive gear bolt and the balancer gear nut can be slackened individually by locking the two gears together, either with the Honda service tool (Pt. No. 07724 - 0010100), or a stout piece of cloth jammed between them, without the risk of any damage should either prove tight.

3. Unscrew the primary gear bolt and remove the bolt and its washer and slide the timing rotor off the crankshaft. Unscrew the balancer gear nut and remove the nut and its washer.

4. Align the teeth of the two halves of the

15.37 Install the ignition pulse generator (a) and the wiring grommet (b)

primary drive gear and the balancer gear and lock the halves together (see Section 15, Step 10), then slide the gears off their shafts.

Inspection

5. The two halves of the primary drive gear and the balancer gear can be separated by easing them apart with a flat-bladed screwdriver after removing the bolt locking the halves together - disassemble each gear separately to avoid interchanging parts. Note how the tabs on the inside of the outer half locate against the spring ends, how the holes align, and how the spring washer fits with its raised outer edge facing out (see illustration).

6. No specifications are available for the springs, but check that they are of equal length and undamaged. Renew all springs as a set. Check the gear teeth for wear or damage and renew if necessary.

7. Inspect the timing rotor - this is not a wearing part but in the unlikely event that the rotor triggers or splines are damaged, the rotor must be renewed.

Installation

8 If the two halves of the balancer gear have been separated, apply molybdenum disulphide grease to the inside face of the outer gear half before assembly and fit the spring washer between the halves with its raised edge facing out. Align the 1 .T mark on the outer gear half with the wide spline on the inner half (see illustration). Align the teeth of the two halves of the gear and lock them together with the bolt used previously.