Operators Manual
Table Of Contents
- Contents
- 1. Introduction and safety precautions
- 2. Specifications
- 3. Troubleshooting
- 4. Clutch
- 5. Engine
- 6. Ignition system
- 6.1 Ignition timing
- 6.2 Ignition module
- 6.3 Testing the ignition module
- 6.4 Spark plug boot / ignition lead
- 6.5 Flywheel
- 6.6 Short circuit wire
- 6.6.1 Testing
- 6.6.2 Short circuit wire on engine, removal and installation
- 6.6.3 Short circuit wire with M-Tronic on engine, removal and installation
- 6.6.4 Short circuit wire on control handle for loop handle, removal and installation
- 6.6.5 Short circuit wire on control handle for bike handle, removal and installation
- 6.6.6 Ground wire
- 6.6.7 Contact spring versions with control handle for bike handle
- 6.7 Troubleshooting, Ignition System
- 7. M-Tronic
- 8. Rewind starter
- 9. Antivibration elements
- 10. Actuating levers
- 11. Fuel system
- 12. Drive tube assembly
- 13. Special tools
- 14. Service accessories
9FS 240 C, FS 260 C, FS 360 C, FS 410 C, FS 460 C-M
3.2 Gearbox
Problem Cause Remedy
Loud noises Ball bearings damaged or worn Replace ball bearings on the drive
side and non-drive side
Pinion damaged or worn Replace set of pinions on the drive
side and non-drive side
Too little or no gear lubricant in
gearbox
Gearbox drive tube assembly
25.4 mm:
Add gear lubricant
Gearbox drive tube assembly
28 mm:
Remove drive pinion and add gear
lubricant
Gearbox becomes too hot Excessive friction due to damaged
or worn ball bearings
Replace ball bearings on the drive
side and non-drive side
Too little or no gear lubricant in
gearbox
Gearbox drive tube assembly
25.4 mm:
Add gear lubricant
Gearbox drive tube assembly
28 mm:
Remove drive pinion and add gear
lubricant
Gearbox runs rough and stops
running under load
Drive shaft does not fully engage
drive pinion
Push gearbox onto drive tube
assembly until the drive shaft fully
engages the drive pinion
Square profile or serration in the
drive train is damaged or worn
Check drive pinion, drive shaft and
clutch drum, replace if necessary
Clutch worn Check clutch and clutch drum,
replace if necessary
Gearbox frozen Locking pin for changing tools not
removed
Remove locking pin
Damaged or worn ball bearings
jammed
Replace ball bearings on the drive
and non-drive sides, also check
bearing seats in the gear housing,
replace gear housing if necessary
Serration damaged or broken –
fragments jammed
Replace set of pinions on the drive
side and non-drive side