TABLE OF CONTENTS
17.4.8
Changing the connecting rod, conrod
bearing, and crank pin ................................. 145
17.4.9
Checking the crankshaft run-out at the
bearing pin ................................................... 146
17.4.10
Measuring the crankshaft end play .............. 147
17.4.11
Removing the drive wheel of the balancer
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
17.4.22
17.4.23
17.4.24
17.4.25
17.4.26
17.4.27
17.4.28
17.4.29
17.4.30
17.4.31
17.4.32
17.4.33
17.4.34
17.4.35
17.4.36
17.4.37
17.4.38
17.4.39
17.4.40
17.5
17.5.1
17.5.2
17.5.3
17.5.4
17.5.5
17.5.6
17.5.7
17.5.8
17.5.9
17.5.10
17.5.11
17.5.12
17.5.13
17.5.14
17.5.15
17.5.16
17.5.17
17.5.18
17.5.19
shaft .............................................................. 147
Installing the drive wheel of the balancer
shaft .............................................................. 147
Cylinder - Nikasil
®
coating ............................ 148
Checking/measuring the cylinder ................. 148
Checking/measuring the piston ................... 148
Measuring the piston/cylinder mounting
clearance...................................................... 149
Checking the piston ring end gap ................ 149
Checking the camshafts ............................... 150
Checking the pivot points of the
camshafts..................................................... 150
Removing the valves .................................... 151
Checking the valves ..................................... 152
Checking the valve springs .......................... 152
Checking the valve spring seat .................... 152
Checking the cam levers .............................. 153
Checking the cylinder head .......................... 153
Installing the valves ...................................... 153
Checking the freewheel. ............................... 154
Removing the freewheel. .............................. 155
Installing the freewheel. ................................ 155
Checking the electric starter drive ............... 156
Checking the timing assembly ..................... 157
Preparing the timing chain tensioner for
installation .................................................... 158
Checking the clutch ..................................... 158
Checking the shift mechanism ..................... 160
Preassembling the shift shaft ....................... 161
Disassembling the main shaft ...................... 161
Disassembling the countershaft ................... 162
Checking the transmission ........................... 162
Assembling the main shaft ........................... 163
Assembling the countershaft ........................ 164
Engine assembly ............................................... 165
Installing the crankshaft ............................... 165
Installing the transmission shafts ................. 166
Installing the shift forks ................................ 166
Installing the shift drum ................................ 166
Installing the shift rails .................................. 167
Installing the left engine case ....................... 167
Installing the spacer ..................................... 168
Installing the timing chain ............................. 168
Installing the primary gear ............................ 168
Installing the force pump .............................. 169
Installing the suction pump .......................... 169
Installing the locking lever ............................ 170
Installing the shift drum locating unit ........... 170
Installing the shift shaft ................................ 171
Installing the clutch basket ........................... 171
Installing the clutch discs ............................. 172
Installing the clutch cover ............................ 172
Installing the water pump cover ................... 173
Installing the starter drive ............................. 17 4
18
19
20
21
22
23
17.5.20
17.5.21
17.5.22
17.5.23
17.5.24
17.5.25
4
Installing the rotor and ignition pulse
generator ...................................................... 1 7 4
Installing the piston ...................................... 17 4
Installing the cylinder head ........................... 176
Installing the camshafts ................................ 177
Installing the timing chain tensioner ............. 177
Checking the valve clearance ...................... 178
17.5.26
Adjusting the valve clearance ....................... 178
17.5.27
Installing the starter motor ........................... 179
17.5.28
Installing the valve cover .............................. 180
17.5.29
Installing the spark plug ............................... 181
17.5.30
Installing the oil filter ..................................... 181
17.5.31
Installing the oil screen ................................. 181
17.5.32
Installing the spacer ..................................... 182
17.5.33
Installing the clutch push rod ....................... 182
17.5.34
Removing the engine from the engine
assembly stand . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . 182
CLUTCH ........................................................................ 183
18.1
Checking/correcting the fluid level of the
hydraulic clutch ................................................. 183
18.2
Changing the hydraulic clutch fluid .................. 183
WATER PUMP, COOLING SYSTEM ............................. 185
19.1
Cooling system ................................................. 185
19.2
Checking the antifreeze and coolant level ........ 185
19.3
Checking the coolant level. ............................... 186
19.4
Draining the coolant.. ........................................ 186
19.5
Refilling with coolant ......................................... 187
LUBRICATION SYSTEM ............................................... 188
20.1
Oil circuit ........................................................... 188
20.2
Checking the engine oil level ............................ 188
20.3
Changing the engine oil and oil filter,
cleaning the oil screen ...................................... 189
20.4
Adding engine oil .............................................. 191
20.5
Checking the engine oil pressure ..................... 191
IGNITION SYSTEM ........................................................ 193
21.1
Ignition coil - checking the secondary
winding .............................................................. 193
21.2
Checking the spark plug connector .................. 193
21.3
Alternator - checking the stator winding ........... 193
21.4
Removing the stator and ignition pulse
generator ........................................................... 194
21.5
Installing the stator and ignition pulse
generator ........................................................... 194
ELECTRIC STARTER ..................................................... 195
22.1
Checking the starter motor ............................... 195
THROTTLE VALVE BODY ............................................. 196
23.1
Adjusting the idle speed ................................... 196
23.2
Executing the initialization run .......................... 196
24 TECHNICAL DATA ........................................................ 198
24.1
Engine ............................................................... 198
24.2
Engine tolerance, wear limits ............................ 198
24.3
24.4
24.4.1
24.4.2
24.4.3
24.5
24.6
24.7
24.8
Engine tightening torques ................................. 199
Capacities . .. . . .. . .. . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . .. . 200
Engine oil ...................................................... 200
Coolant......................................................... 200
Fuel ............................................................... 200
Chassis . . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . 201
Electrical system............................................... 201
Tires .................................................................. 201
Fork ................................................................... 202
