68
CD927A
8. Lubricate the magneto cover gasket with fresh
engine oil; then place it into position on the two
alignment pins. Make sure the outer shift shaft
washer is in place.
PR431A
9. Install the magneto cover and secure with the cap
screws. Tighten only until snug.
10. Place the bushing into position on the crankshaft
making sure a new, lubricated O-ring is inside the
bushing. Tighten the flange nut to 25 ft-lb.
11. Using a crisscross pattern, tighten the cap screws
(from step 9) to 8 ft-lb.
12. Clean the countershaft and trigger splines thoroughly
and install the inner snap ring onto the shaft; then
apply green Loctite #620 to the trigger and counter-
shaft splines and install the trigger. Secure with a flat
washer and outer snap ring.
GZ253
GZ254
13. Using a new gasket, install the speed sensor housing
onto the crankcase and secure with two cap screws.
Tighten to 8 ft-lb.
CD069
14. Place the water pump into position and secure with
two cap screws. Tighten to 8 ft-lb.
NOTE: Ensure the slotted water pump shaft is
aligned with the groove in the counter balancer shaft.
15. Install the crossover tube on the water pump and cylinder
head making sure the O-ring is properly positioned.
16. On the XT, install the shift arm on the shift arm shaft
making sure the scribed marks (from removing) are
aligned. Tighten securely.
17. Place the outer magneto cover into position on the
left-side cover; then tighten four cap screws to 6 ft-lb.
Left-Side Components
NOTE: For efficiency, it is preferable to remove and
disassemble only those components which need to be
addressed and to service only those components. The
technician should use discretion and sound judgment.
NOTE: The engine/transmission does not have to
be removed from the frame for this procedure.
AT THIS POINT
To service any one specific component, only limited dis-
assembly of components may be necessary. Note the
AT THIS POINT information in each sub-section.