550H (Maxim)

Transmission Assembly

Submitted by xjcdadmin on Fri, 06/18/2010 - 01:46

1. Upper crankcase

a. Install the connecting rods onto the crankshaft with the proper connecting rod bearings and apply molybedenum disulfide grease to the bolt threads. Apply torque evenly to both ends of the cap.

Clutch Adjustment

Submitted by xjcdadmin on Fri, 06/18/2010 - 01:46

Free play adjustment

a.   Loosen either the handlebar lever adjuster lock nut or the cable length adjuster lock nut.

b.  Turn the cable length adjuster either in or out until proper lever free play is achieved.

Clutch lever free play:

2 - 3mm (0.08 ~ 0.12 in)

Clutch and Oil Pump

Submitted by xjcdadmin on Fri, 06/18/2010 - 01:46

Clutch

1. Remove right crankcase cover.

2. Release the tension evenly on the 6 mm bolts and remove the clutch pressure plate and clutch springs.

3.    Remove the friction plates and clutch plates.

Spark Plug

Submitted by xjcdadmin on Fri, 06/18/2010 - 01:46

1. Check the electrode condition and wear, insulator color and electrode gap.

2.    Use a wire gauge for measuring the plug gap.

3.    If the electrodes become too worn, replace the spark plug.

4.    When installing the plug, always clean the gasket surface. Wipe off any grime that might be present on the surface of the spark plug, and torque the spark plug properly.

Clutch

Submitted by xjcdadmin on Fri, 06/18/2010 - 01:46

Clutch assembly

a. Install the primary drive gear and collar.

Tightening torque: 5.0 m-kg (36.0 ft-lb)

b- Install the primary driven gear assembly.

c. Install the clutch boss and thrust plate.

Fuel Petcock

Submitted by xjcdadmin on Fri, 06/18/2010 - 01:46


If the fuel petcock is
leaking or excessively contaminated, it should be removed from the fuel
tank and inspected.

1.   
Remove the fuel tank and position it so that fuel will not spill when
the petcock is removed.

2.   
Remove the petcock and inspect the filter screen. Replace the filter if
seriously contaminated.

Oil Pump and Clutch

Submitted by xjcdadmin on Fri, 06/18/2010 - 01:46

Oil pump

1. Check the clearance between housing and outer rotor.

Standard clearance:

0.09 ~ 0.15 mm (0.0035 ~ 0.0059 in)

2. Check the clearance between outer rotor and inner rotor.

Standard clearance: 0.03 ~ 0.09 mm (0.0012 ~ 0.0035 in)

3. Check the plunger for scrathces and wear.