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Compare with any other bike. Displacement :. Cap 2. Fork cap bolt down to distribute the oil. If the steering head is loose, adjust it. The spring preload of the rear shock absorber can Loosen the front fork pinch bolts and steer- be adjusted to suit rider's preference, weight, and ing stem bolt.
Page Front Wheel Front wheel Fuel cock If either fuel cock is leaking or is excessively con- taminated, it should be removed from the fuel tank and inspected. Raise the front end of the motorcycle, and spin the wheel by hand. Touch the axle or 1. Tires and wheels should be balanced when- This motorcycle is equipped with aluminum wheels ever either one is changed or replaced. Fail- designed to be compatible with either tube or tube- ure to have a wheel assembly balanced can less tires.
Page Headlight Headlight Headlight bulb replacement 1. Remove the two screws holding the light unit assembly to the headlight body. Holding screw 2. Disconnect the lead wires and remove the light unit assembly. The fuse block is located under the seat. Avoid touching the glass part of the bulb. Also keep it free from oil; otherwise, the transparency of the glass, life of the bulb, and illuminous flux will be adversely affected.
If oil gets on the lamp, clean it with a cloth moistened thoroughly with alcohol or lacquer thinner. Preparation for removal…………………………………………………………………………………….. Fuel tank………………………………………………………………………………………………………. Air filter and air baffle plate……………………………………………………………………………… Exhaust pipes and mufflers………………………………………………………………………………..
Leads and couplers…………………………………………………………………………………………. Cables and pipes…………………………………………………………………………………………….. Footrests and sidestand……………………………………………………………………………………. Engine removal………………………………………………………………………………………………. Carburetors, rear exhaust pipes, and inlet pipe………………………………………………………. Water pump cover and pipe joints………………………………………………………………………..
Crankcase assembly………………………………………………………………………………………….. Front-cylinder chain guide and drive gears………………………………………………………………. Rear-cylinder chain guide and drive gears………………………………………………………………..
Balancer gear and flywheel………………………………………………………………………………….. Starter motor and starter idle gear 1……………………………………………………………………… Crankcase covers, oil pump, and oil filter………………………………………………………………… Pistons, cam chain guides, and cylinders………………………………………………………………… Page Chapter 3. Preparation for removal 1. All dirt, mud, dust, and foreign material must be cleaned from the engine before the en- 1.
Page Battery 5. Drain the cooling system: First, remove the Battery 1. Disconnect the battery leads. Then remove the two cylinder drain plugs, the main drain plug, and finally, remove the NOTE: thermostatic cover. This will ensure that the Disconnect the negative lead first. Page Leads And Couplers 1.
Thermostatic switch Leads and couplers Cables and pipes 1. Remove the T. I, unit bracket and reser- 1. Disconnect the following cables. Page Engine Removal Engine removal NOTE: In addition to the engine mounting bracket cylinder, four mounting bolts hold the engine in place: a thru- bolt, a large threaded stud, and one bolt on each side of the engine.
First, remove the right side frame tube and the engine mounting bracket. Remove the carburetor joint from each cyl- Cylinder head covers, cylinder heads, and inder. Remove the exhaust pipe clamp and 1. Remove the spark plug from each cylinder.
Remove 2. Remove the engine mounting bracket Page 45 6. Remove the cam chain tensioner from each cylinder head and remove the cam sprock- ets. Cam chain tensioner 1. Allen wrench 7. Remove each cylinder head. Loosen all the 8. Remove the three dowels and 0-ring from cylinder head nuts and bolts first. Each nut each cylinder. Page Piston Pin And Piston 2. Remove the oil filter element. Piston pin and piston 1. Mark each piston so it can be reinstalled in 3.
Remove the right side crankcase cover the appropriate cylinder. Remove the piston pin clip from the pis- ton. Page Flywheel 8. Disconnect the neutral switch and oil pres- Flywheel sure switch leads. Place a piece of rolled rag or a piece of lead between the primary gears, and remove the flywheel securing nut. Oil pressure switch 2. Neutral switch 9. Use care so that they don't fall out when re- moving the balancer drive gear.
Idle gear 2 2. Electric starter switch 3. Remove the woodruff key from the crank- shaft key way. Page Shifter 1. Remove the timing gear stopper bolt, then 6. Flatten the lock tab on the primary-drive remove the shaft. Place a small piece of rolled rag or a small piece of lead between the primary gears, and remove the primary drive gear securing nut, lock washer, washer and key.
Page Crankcase 2. Disengage the shift lever from the shift 2. Remove the rightside crankcase from the drum pins, and remove the shift shaft as- leftside, and remove the three dowels. Page 51 3. Remove the crankshaft and the balancer shaft from the left side crankcase. Circlip 2. Crankshaft 2. Balancer shaft 4. Page Inspection And Repair Mount the valve spring compressor on the use the torx driver. Re- move the valve retainers with a magnet or tweezers, and remove the valve springs.
Check the valve face and the stem end for wear. Page 54 1. Valve guide installer 2. Valve guide remover Valve guides 4. After installing the valve guide, use the If oil leaks into the cylinder through a valve 6mm 0. Page 55 3. If the valve seat is uniform around the pe- CAUTION: rimeter of the valve face but is too wide or If the valve seat is obviously pitted or worn, it not centered on the valve face, it must be should be cleaned with a valve seat cutter.
If a retainer has not been prop- erly installed, it could be ejected from the cylin- der head. Gently tap the end of the valve stem with a plastic mallet. This will ensure that the re- tainers are properly seated in the collar.
Camshaft-to-cap clearance: Standard: 0. Page Cylinder 6. Cam chain dampers Inspect the top cam chain damper stopper guide and two 2 vertical slipper-type dampers for excessive wear. Any that shows excessive wear should be replaced. Worn dampers may indicate an improperly adjusted or worn-out cam chain. Cylinder Piston and piston rings 1. Page 60 Piston ring The oversize top and middle ring sizes are stamped on top of the ring. The expander spacer of the bottom ring oil control ring is color-coded to identify sizes.
The color mark is painted on the expander spacer. Page Crankcase Crankcase 1. Thoroughly wash the case halves in a mild solvent. Clean all gasket mating surfaces and crankcase mating surfaces thoroughly.
Visually inspect the case halves for any cracks, road damage, etc. Replace the crankcase as required. Check the oil-delivery passage for signs of blockage. Pry oil seal s out of place with a screwdriver. If either of the right- or left-side main bearings is Replace all oil. Page 63 1. As shown in the photo, set the special tool CAUTION: set, and using a hydraulic press, pull the The diameter of counterbore should be meas- main bearing out to the outside of the ured at two places, and the average of the two crankcase.
Page 64 5. Apply molybdenum disulfide grease to the bolt threads, and torque both ends of the rod cap evenly. Do not move the connecting rod until the clearance check is completed. Once you reach 3. Page Oil Pump The connecting rod numbers are stamped in ink on the rod. Rotor-to-housing clearance: 0.
Use the Primary drive color code to choose the proper bearing. The drive gear is mounted on the crankshaft; Page 66 Standard Wear limit Friction plate 2. Check the clutch housing bearing for dam- age.
If damaged, replace the bearing. Clutch boss The clutch boss contains a built-in damper beneath the first clutch plate clutch plate 2.
Page Transmission Bend limit: 0. Check the cam followers on each shift fork for wear. Check the ends that ride in the grooves in the shift cam. If they are worn or Clutch springs damaged, replace the shift fork. Page Starter Drives After installing the pinions onto the main Check the transmission shafts using a cen- axle, make sure the 4th and 5th pinions tering device and dial gauge. If any shaft is turn freely around the main axle. When installing oil seal s , apply a Important information light coating of lightweight lithium base Gaskets and seals grease to the seal lips s.
When installing 1. All gaskets and seals should be replaced bearings liberally oil the bearings. Page Left-Side Crankcase Left-side crankcase 2. Install the drive axle assembly with the 1. Press the crankshaft bearing, balancer shaft proper shims refer to page Be sure bearing, and transmission bearing into the that the bearing is properly seated against left side crankcase.
Liberally oil the bear- the crankcase. Page 71 3. Install the bearing stopper plates and 7. Install the shift cam into the left side crankcase. Install the shift fork 2 onto the third pinion. Use the Then insert the guide bar short one into the Torx driver and torque the bolts to specifica- crankcase through the shift fork.
If tightening is interrupted between 3. Tighten to full-torque specification without pausing. Page Right-Side Crankcase Apply pressure to the outer race of the bearing. Page Shifter Tightening torque: 10 Nm 1. Shift shaft oil seal 2. Install the shifter into the right side crank- case. Hook the shift-cam-stopper spring beneath the projection in the crankcase.
Install the washer and circlip onto the shift 3. Study the zero-lash timing gear. Note that it shaft. One set is spring loaded and moves relative to the other set. Washer 2. Circlip Front-cylinder chain guide and drive gears. Page 76 6. Lower the timing gear into the cam chain journal. Timing gear shaft 9. Install the primary drive gear 33T , oil pump drive gear 23T , plate washer, lock washer, and nut.
Finger-tighten the securing 7. The punch mark on the timing gear should nut, do not torque it at this point. Page Clutch Clutch Page 78 1. Install the clutch housing onto the trans- mission main axle. Install the thrust washer and the clutch boss onto the transmission main axle.
Install the friction and clutch plates. Begin with a friction plate and alternate clutch and friction plates until all of the plates are in the clutch boss. By turning the crankshaft by hand, bring the key position with the center of the rear cyl- inder bore. Rear-cylinder chain guide and drive gears 4. Attach a proper length of wire to the cam chain, and place the cam chain around the timing-gear sprocket 2. Page Balancer Gear And Flywheel The balancer driven gear damper assem- Tightening torque: bly is composed of 6 springs and 3 pins.
Stopper bolt: 12 Nm 1. Then install the damper springs; Place a small piece of rolled rag or a piece 9. Install the washer and the flywheel securing of lead between the primary gears. This will bolt onto the crankshaft. Place a small piece hold the balancer drive gear so you can of rolled rag or a piece of lead between the tighten the securing nuts. Install the left side crankcase cover. Use a new gasket and torque the securing bolts to specification.
NOTE: Install the bolt with the clutch cable clamp as shown in the illustration. Tightening torque: 10 Nm 1m - kg, 7. Install the right side crankcase cover. NOTE: Place the bolt with the starter motor lead clamp as shown in the illustration. O-ring 7. Install the oil pump assembly and oil baffle into the right side crankcase. Page 84 2. Align the piston rings as shown.
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