TABLE OF CONTENTS
15. 7
Checking the capacitor ..................... 133
15.8
Checking the starter relay ................. 134
16 BRAKE SYSTEM ........................................... 135
16.1
16.2
16.3
16.4
16.5
16.6
16.7
16.8
16.9
Checking the front brake linings ....... 135
Changing the front brake linings ....... 135
Checking the free travel of the
hand brake lever . . .. . . .. . .. . .. . .. . .. . .. . .. . .. . . 137
Adjusting the basic position of the
hand brake lever . . .. . . .. . .. . .. . .. . .. . .. . .. . .. . . 137
Checking the front brake fluid
level ................................................... 138
Adding front brake fluid .................... 139
Changing the front brake fluid .......... 140
Checking the brake linings of the
rear brake.......................................... 142
Changing the rear brake linings ........ 142
16.10 Checking the free travel of foot
brake lever . . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . .. . . 144
16.11 Adjusting the basic position of the
foot brake lever................................. 145
16.12 Checking the rear brake fluid level ... 145
16.13 Adding rear brake fluid ..................... 146
16.14 Changing the rear brake fluid ........... 147
17 ENGINE ......................................................... 150
4
17.1
Removing the engine ........................ 150
17.2
Installing the engine .......................... 157
17 .3
Engine disassembly .......................... 165
17.3.1
17.3.2
17.3.3
17.3.4
17.3.5
17.3.6
17.3.7
17.3.8
17.3.9
17.3.10
17.3.11
17.3.12
17.3.13
17.3.14
17.3.15
17.3.16
17.3.17
17.3.18
17.3.19
17.3.20
Preparations................................. 165
Removing the clutch push rod ..... 165
Draining the engine oil. ................. 165
Removing the oil filter ................... 166
gear position sensor, removing .... 167
Removing the spark plug ............. 167
Removing the valve cover ............ 167
starter motor, removing ................ 168
Positioning the engine at
ignition top dead center ............... 169
Removing the timing chain
tensioner ....................................... 169
Removing the camshafts .............. 170
cylinder head, removing ............... 170
Removing the piston .................... 171
rotor, removing ............................. 171
starter drive, removing ................. 172
Removing the suction pump ........ 172
water pump impeller, removing .... 173
Removing the clutch cover ........... 17 4
Removing the clutch discs ........... 17 4
Removing the clutch basket ......... 175
17.3.21
primary gear, removing ................ 176
17.3.22
timing chain, removing ................. 176
17.3.23
Removing the force pump ............ 176
17.3.24
Removing the locking lever .......... 177
17.3.25
shift drum locating unit,
removing ....................................... 178
17.3.26
shift shaft, removing ..................... 178
17.3.27
spacer, removing .......................... 178
17.3.28
left engine case, removing ........... 178
17.3.29
shift rails, removing ...................... 179
17.3.30
Removing the shift drum .............. 179
17.3.31
shift forks, removing ..................... 180
17.3.32
Removing the transmission
shafts ............................................ 180
17.3.33
Removing the crankshaft ............. 180
17.4
Working on individual parts .............. 181
17.4.1
Working on the right section of
17.4.2
17.4.3
17.4.4
17.4.5
17.4.6
17.4.7
17.4.8
17.4.9
17.4.10
17.4.11
17.4.12
17.4.13
17.4.14
17.4.15
17.4.16
17.4.17
17.4.18
17.4.19
17.4.20
17.4.21
the engine case ............................ 181
Working on the left section of
the engine case ............................ 183
Work on the clutch cover . . .. . .. . .. . . . 184
Checking the oil pressure
regulator valve .............................. 186
Checking the lubrication
system .......................................... 187
Removing the crankshaft
bearing inner race ......................... 187
Installing the crankshaft bearing
inner race ...................................... 188
connecting rod, conrod bearing,
and crank pin, changing ............... 188
Checking the crankshaft run-out
at the bearing pin ......................... 190
Measuring the crankshaft end
play ............................................... 191
Removing the drive wheel of the
balancer shaft ............................... 191
Installing the drive wheel of the
balancer shaft ............................... 192
Cylinder - Nikasil
®
coating ............ 192
Checking/measuring the
cylinder ......................................... 192
piston, checking/measuring ......... 193
Measuring the piston/cylinder
mounting clearance...................... 194
Checking the piston ring end
gap ............................................... 194
camshafts, checking .................... 195
Checking the pivot points of the
camshafts..................................... 195
valves, removing .......................... 196
valves, checking ........................... 197
