Note: On XL models, the timing rotor is mounted on the right-hand end of the crankshaft along with the primary drive gear.
On XRV models, the ignition timing triggers are incorporated in the alternator rotor, so ignore references to the rotor when removing the primary drive gear.
Removal
1. Remove the clutch (see Section 18).
2. On XL models, remove the ignition pulse generator coil(s) (see Chapter 5).
3. To unscrew the primary drive gear bolt the crankshaft must be prevented from turning. To do this, either unscrew the crankshaft end cap from the alternator cover (see illustration 9.2a) and counter-hold the crankshaft using a socket on the alternator rotor bolt (there is no danger of the bolt coming undone as it has a left-hand thread, and no danger if it being overtightened as it has a higher torque setting than the primary drive gear bolt), or alternatively obtain the gear-jamming tool (part No.07724-0010100), then refit the clutch housing and locate the tool between the primary drive and driven gears at the top.
4. With the crankshaft locked, unscrew the primary drive gear bolt and remove the washer (see illustrations). On XL models remove the timing rotor, noting how it fits (see illustration).
21.4a. Unscrew the bolt (arrowed)...
21.4b ... ocking the crankshaft as described...
21.4c ...and on XL models remove the timing rotor
5. Slide the primary drive gear off the end of the crankshaft, noting which way round it fits (see illustration).
21.5. Slide the primary drive gear off the shaft
Inspection
6. Check the teeth of the primary drive gear and the corresponding teetn of the primary driven gear on the back of the clutch housing. Renew the clutch housing and/or primary drive gear if worn or chipped teeth are discovered.
Installation
7. Slide the primary drive gear onto the crankshaft, aligning the wide splines, and making sure on XL models the 'OUT' mark on the gear faces outwards, and on XRV models the thinner sub-gear is on the outside (see illustration).
21.7. Slide the primary drive gear onto the shaft...
8. On XL models install the timing rotor, aligning the wide splines (see illustration).
21.8 ...and on XL models the timing rotor
9. Install the bolt with its washer and tighten it finger-tight (see illustration 21.4c). Lock the crankshaft using the same method as on removal (see Step 3). With the crankshaft locked, tighten the primary drive gear bolt to the torque setting specified at the beginning of the Chapter (see illustration). Note that if you are using the alternator rotor bolt to counter-hold the crankshaft there should be no danger of it coming loose as it is set to a higher torque setting.
21.9. Tighten the bolt to the specified torque
10. On XL models, install the ignition pulse generator coil(s) (see Chapter 5).
11. Install the clutch (see Section 18).