INDEX
crankshaft bearing inner race, removing . . . 187
crankshaft end play, measuring . . . . . . . . . 191
crankshaft run-out, checking at bearing pin . 190
cylinder -
Nikasil
®
coating . . . . . . . . . . . . 192
cylinder head, checking . . . . . . . . . . . . . . 199
cylinder, checking/measuring . . . . . . . . . . 192
drive wheel of balancer shaft, removing . . . 191
electric starter drive, checking . . . . . . . . . . 202
freewheel, checking . . . . . . . . . . . . . . . . . 200
ignition pulse generator, installing
250
lubrication system, checking . . . . . . . . . . . 187
oil pressure regulator valve, checking . . . . . 186
piston ring end gap, checking . . . . . . . . . . 194
piston/cylinder, mounting clearance measur-
ing ............................. 194
pivot points of camshafts, checking . . . . . . 195
shift shaft, preassembling . . . . . . . . . . . . . 207
stator, installing .................... 250
timing assembly, checking . . . . . . . . . . . . 203
timing chain tensioner, preparing for installa-
tion ............................ 204
valve spring seat, checking . . . . . . . . . . . . 198
Engine - work on the individual parts
camshafts, checking
195
connecting rod, conrod bearing, and crank
pin, changing .................... .
188
countershaft, assembling . . . . . . . . . . . . . 212
crankshaft position sensor, removing . . . . . 250
Disassembling the countershaft . . . . . . . . . 209
drive wheel of the balancer shaft, installing . 192
freewheel, installing . . . . . . . . . . . . . . . . . 201
freewheel, removing . . . . . . . . . . . . . . . . . 201
left engine case section . . . . . . . . . . . . . . 183
main shaft, assembling . . . . . . . . . . . . . . . 211
main shaft, disassembling . . . . . . . . . . . . . 208
piston, checking/measuring
193
Removing the stator . . . . . . . . . . . . . . . . . 250
right engine case section
181
shift mechanism, checking . . . . . . . . . . . . 206
transmission, checking ............... 209
valve springs, checking . . . . . . . . . . . . . . 198
valves, checking
valves, installing
valves, removing
Engine - working on the individual parts
clutch, checking
Engine assembly
197
199
196
205
camshafts, installing . . . . . . . . . . . . . . . . . 227
Checking the valve clearance . . . . . . . . . . 228
clutch basket, installing . . . . . . . . . . . . . . 220
304
clutch cover, installing . . . . . . . . . . . . . . . 221
clutch discs, installing
221
clutch push rod, installing . . . . . . . . . . . . . 234
crankshaft, installing . . . . . . . . . . . . . . . . . 213
cylinder head, installing
226
engine, removing from the engine assembly
stand ........................... 234
force pump, installing . . . . . . . . . . . . . . . . 217
gear position sensor, installing . . . . . . . . . . 232
left engine case, installing . . . . . . . . . . . . . 215
locking lever, installing . . . . . . . . . . . . . . . 216
oil filter, installing . . . . . . . . . . . . . . . . . . . 232
oil screen, installing . . . . . . . . . . . . . . . . . 233
piston, installing . . . . . . . . . . . . . . . . . . . . 224
primary gear, installing . . . . . . . . . . . . . . . 219
rotor, installing . . . . . . . . . . . . . . . . . . . . . 224
shift drum locating unit, installing . . . . . . . . 216
shift drum, installing . . . . . . . . . . . . . . . . . 214
shift forks, installing . . . . . . . . . . . . . . . . . 214
shift rails, installing . . . . . . . . . . . . . . . . . . 214
shift shaft, installing . . . . . . . . . . . . . . . . . 216
spacer, installing . . . . . . . . . . . . . . . . . . . 216
spark plug, installing . . . . . . . . . . . . . . . . 232
starter drive, installing . . . . . . . . . . . . . . . 223
starter motor, installing . . . . . . . . . . . . . . . 230
suction pump, installing . . . . . . . . . . . . . . 218
timing chain tensioner, installing
timing chain, installing
227
219
transmission shafts, installing . . . . . . . . . . 213
valve clearance, adjusting . . . . . . . . . . . . . 229
valve cover, installing ................ 231
water pump cover, installing
222
Engine disassembly
Camshafts, removing . . . . . . . . . . . . . . . . 170
clutch basket, removing . . . . . . . . . . . . . . 175
clutch cover, removing . . . . . . . . . . . . . . . 17 4
clutch discs, removing . . . . . . . . . . . . . . . 174
clutch push rod, removing . . . . . . . . . . . . . 165
crankshaft, removing . . . . . . . . . . . . . . . . 180
cylinder head, removing . . . . . . . . . . . . . . 170
draining the engine oil
165
engine, positioning at ignition top dead center 169
force pump, removing . . . . . . . . . . . . . . . 176
gear position sensor, removing . . . . . . . . . 167
left engine case, removing . . . . . . . . . . . . 178
locking lever, removing . . . . . . . . . . . . . . . 177
oil filter, removing
166
piston, removing . . . . . . . . . . . . . . . . . . . 171
preparations . . . . . . . . . . . . . . . . . . . . . . 165
primary gear, removing . . . . . . . . . . . . . . . 176
