CRANKCASE
...5-36 REMOVING THE CLUTCH ...5-40 CHECKING THE FRICTION PLATES...5-40 CHECKING THE CLUTCH PLATES...5-40 CHECKING THE CLUTCH SPRINGS...5-41 CHECKING THE CLUTCH HOUSING...5-41 CHECKING THE CLUTCH BOSS...5-41 CHECKING THE PRESSURE PLATE ...5-41 CHECKING THE CLUTCH PUSH LEVER
AND SHORT CLUTCH PUSH ROD...5-41 CHECKING THE PRIMARY DRIVE GEAR...5-41 CHECKING THE PRIMARY DRIVEN GEAR ...5-42 INSTALLING THE CLUTCH...5-42 ...5-45 CHECKING THE OIL PUMP ...5-47 ASSEMBLING THE OIL PUMP...5-47 INSTALLING THE OIL PUMP ...5-48 ...5-49 CHECKING THE SHIFT SHAFT ...5-50 CHECKING THE STOPPER LEVER ...5-50 INSTALLING THE SHIFT SHAFT ...5-50 ...5-51 REMOVING THE PRIMARY DRIVE GEAR AND
BALANCER GEARS...5-53 CHECKING THE BALANCER GEARS
AND PRIMARY DRIVE GEAR ...5-53 ASSENBLING THE BALANCER DRIVEN GEAR ...5-53 INSTALLING THE PRIMARY DRIVE GEAR AND
BALANCER GEARS...5-53 ...5-55 SEPARATING THE CRANKCASE...5-58 CHECKING THE CRANKCASE...5-58 CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE...5-58 CHECKING THE OIL STRAINER ...5-58 CHECKING THE BEARINGS AND OIL SEAL ...5-58 INSTALLING THE BEARING RETAINER...5-59 ASSEMBLING THE CRANKCASE...5-59
CRANKSHAFT
TRANSMISSION
...5-60 REMOVING THE CRANKSHAFT ...5-61 CHECKING THE CRANKSHAFT...5-61 INSTALLING THE CRANKSHAFT...5-61 ...5-63 CHECKING THE SHIFT FORKS...5-66 CHECKING THE SHIFT DRUM ASSEMBLY...5-66 CHECKING THE TRANSMISSION...5-66 CHECKING THE CLUTCH PUSH RODS ...5-67 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE ...5-67 INSTALLING THE SHIFT FORKS AND SHIFT DRUM ASSEMBLY ....5-67
CLUTCH
OIL PUMP
SHIFT SHAFT
BALANCER GEAR
CRANKCASE
...5-36 REMOVING THE CLUTCH ...5-40 CHECKING THE FRICTION PLATES...5-40 CHECKING THE CLUTCH PLATES...5-40 CHECKING THE CLUTCH SPRINGS...5-41 CHECKING THE CLUTCH HOUSING...5-41 CHECKING THE CLUTCH BOSS...5-41 CHECKING THE PRESSURE PLATE ...5-41 CHECKING THE CLUTCH PUSH LEVER
AND SHORT CLUTCH PUSH ROD...5-41 CHECKING THE PRIMARY DRIVE GEAR...5-41 CHECKING THE PRIMARY DRIVEN GEAR ...5-42 INSTALLING THE CLUTCH...5-42 ...5-45 CHECKING THE OIL PUMP ...5-47 ASSEMBLING THE OIL PUMP...5-47 INSTALLING THE OIL PUMP ...5-48 ...5-49 CHECKING THE SHIFT SHAFT ...5-50 CHECKING THE STOPPER LEVER ...5-50 INSTALLING THE SHIFT SHAFT ...5-50 ...5-51 REMOVING THE PRIMARY DRIVE GEAR AND
BALANCER GEARS...5-53 CHECKING THE BALANCER GEARS
AND PRIMARY DRIVE GEAR ...5-53 ASSENBLING THE BALANCER DRIVEN GEAR ...5-53 INSTALLING THE PRIMARY DRIVE GEAR AND
BALANCER GEARS...5-53 ...5-55 SEPARATING THE CRANKCASE...5-58 CHECKING THE CRANKCASE...5-58 CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE...5-58 CHECKING THE OIL STRAINER ...5-58 CHECKING THE BEARINGS AND OIL SEAL ...5-58 INSTALLING THE BEARING RETAINER...5-59 ASSEMBLING THE CRANKCASE...5-59
CRANKSHAFT
TRANSMISSION
...5-60 REMOVING THE CRANKSHAFT ...5-61 CHECKING THE CRANKSHAFT...5-61 INSTALLING THE CRANKSHAFT...5-61 ...5-63 CHECKING THE SHIFT FORKS...5-66 CHECKING THE SHIFT DRUM ASSEMBLY...5-66 CHECKING THE TRANSMISSION...5-66 CHECKING THE CLUTCH PUSH RODS ...5-67 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE ...5-67 INSTALLING THE SHIFT FORKS AND SHIFT DRUM ASSEMBLY ....5-67
5-1 5-2
ENGINE REMOVAL ENGINE REMOVAL
ENGINE REMOVAL
Disconnecting the leads and couplers
Order Job/Parts to remove Qty Remarks
CAUTION:
First, disconnect the negative battery lead, and then the positive battery lead. Negative battery lead/Positive battery lead Refer to “CHECKING AND CHARGING
THE BATTERY” on page 3-25.
Engine oil Drain.
Refer to “CHANGING THE ENGINE OIL” on page 3-10.
Coolant Drain.
“CHANGING THE COOLANT” on page 3-14 Seat/Side panel/Front panel/Air filter case Refer to “GENERAL CHASSIS” on page
4-1.
Fuel tank Refer to “FUEL TANK ” on page 7-1.
Throttle body/Intake manifold Refer to “THROTTLE BODY” on page 7-4.
Water pump breather hose/Radiator outlet
hose/Radiator inlet hose/Radiator Refer to “RADIATOR” on page 6-1.
Air cut-off valve/Reed valve/Plate Refer to “AIR INDUCTION SYSTEM” on page 7-9.
Drive sprocket cover/Drive sprocket Refer to “CHAIN DRIVE” on page 4-60.
1 Spark plug cap 1 Disconnect.
10 Nm (1.0 m•kg, 7.2 ft Ib)•
10 Nm (1.0 m•kg, 7.2 ft Ib)•
9 Nm (0.9 m•kg, 6.5 ft Ib)•
Removing the muffler
Order Job/Parts to remove Qty Remarks
1 Muffler end cap 1
2 Muffler protector 1
3 Muffler 1
4 Exhaust pipe gasket 1
For installation, reverse the removal proce-dure.
4
3 2
1
TR
.. 20 Nm (2.0 m•kg, 14 ft Ib)•
TR.
. 15 Nm (1.5 m•kg, 11 ft Ib)•
T
.R. 8 Nm (0.8 m• kg, 5.8 ft Ib)•
5-1 5-2
ENGINE REMOVAL ENGINE REMOVAL
ENGINE REMOVAL
Disconnecting the leads and couplers
Order Job/Parts to remove Qty Remarks
CAUTION:
First, disconnect the negative battery lead, and then the positive battery lead.
Negative battery lead/Positive battery lead Refer to “CHECKING AND CHARGING THE BATTERY” on page 3-25.
Engine oil Drain.
Refer to “CHANGING THE ENGINE OIL” on page 3-10.
Coolant Drain.
“CHANGING THE COOLANT” on page 3-14 Seat/Side panel/Front panel/Air filter case Refer to “GENERAL CHASSIS” on page
4-1.
Fuel tank Refer to “FUEL TANK ” on page 7-1.
Throttle body/Intake manifold Refer to “THROTTLE BODY” on page 7-4.
Water pump breather hose/Radiator outlet
hose/Radiator inlet hose/Radiator Refer to “RADIATOR” on page 6-1.
Air cut-off valve/Reed valve/Plate Refer to “AIR INDUCTION SYSTEM” on page 7-9.
Drive sprocket cover/Drive sprocket Refer to “CHAIN DRIVE” on page 4-60.
1 Spark plug cap 1 Disconnect.
1
3 2
3
7
4 5
8
TR.. 10 Nm (1.0 m•kg, 7.2 ft Ib)•
TR.. 10 Nm (1.0 m•kg, 7.2 ft Ib)•
6
TR.
. 9 Nm (0.9 m•kg, 6.5 ft Ib)•
Removing the muffler
1 Muffler end cap 1
2 Muffler protector 1
3 Muffler 1
4 Exhaust pipe gasket 1
For installation, reverse the removal proce-dure.
4
3 2
1 20 Nm (2.0 m•kg, 14 ft Ib)•
15 Nm (1.5 m•kg, 11 ft Ib)•
8 Nm (0.8 m• kg, 5.8 ft Ib)•
5-3 5-4
ENGINE REMOVAL ENGINE REMOVAL
2 Coolant temperature sensor coupler 1 Disconnect.
3 Stator coil coupler/Crankshaft position sensor
coupler 1/1 Disconnect.
4 Neutral switch connector 1 Disconnect.
5 Starter motor lead 1 Disconnect.
6 Clutch cable 1 Disconnect.
7 Negative battery lead 1 Disconnect.
8 Shift arm 1
For installation, reverse the removal proce-dure.
Disconnecting the leads and couplers
Order Job/Parts to remove Qty Remarks
1
3 2
3
7
4 5
8
TR.. 10 Nm (1.0 m•kg, 7.2 ft Ib)•
TR.
. 10 Nm (1.0 m•kg, 7.2 ft Ib)•
6
TR
.. 9 Nm (0.9 m•kg, 6.5 ft Ib)•
Removing the engine
Order Job/Parts to remove Qty Remarks
NOTE:
Place a suitable stand under the engine. 1 Engine mounting bolt/nut (front side) 1/1
2 Engine mounting bolt/nut (rear lower side) 1/1 3 Engine mounting bolt/nut (rear upper side) 1/1
4 Engine 1
For installation, reverse the removal proce-dure.
49 Nm (4.9 m•kg, 35 ft Ib)• 49 Nm (4.9 m•kg, 35 ft Ib)•
5-3 5-4
ENGINE REMOVAL ENGINE REMOVAL
2 Coolant temperature sensor coupler 1 Disconnect.
3 Stator coil coupler/Crankshaft position sensor
coupler 1/1 Disconnect.
4 Neutral switch connector 1 Disconnect.
5 Starter motor lead 1 Disconnect.
6 Clutch cable 1 Disconnect.
7 Negative battery lead 1 Disconnect.
8 Shift arm 1
For installation, reverse the removal proce-dure.
Disconnecting the leads and couplers
Order Job/Parts to remove Qty Remarks
10 Nm (1.0 m•kg, 7.2 ft Ib)• 10 Nm (1.0 m•kg, 7.2 ft Ib)•
9 Nm (0.9 m•kg, 6.5 ft Ib)•
Removing the engine
Order Job/Parts to remove Qty Remarks
NOTE:
Place a suitable stand under the engine.
1 Engine mounting bolt/nut (front side) 1/1 2 Engine mounting bolt/nut (rear lower side) 1/1 3 Engine mounting bolt/nut (rear upper side) 1/1
4 Engine 1
For installation, reverse the removal proce-dure.
2
3 3
4
1 1
2
T
..R 49 Nm (4.9 m•kg, 35 ft Ib)•
TR
.. 49 Nm (4.9 m•kg, 35 ft Ib)•
E E
E
5-5 5-6