TABLE OF CONTENTS
16 BRAKE SYSTEM ........................................... 132
16.1
Checking the front brake linings ....... 132
16.2
Changing the front brake linings ....... 132
16.3
Checking the free travel of the
hand brake lever . . .. . . .. . .. . .. . .. . .. . .. . .. . .. . . 134
16.4
Adjusting the basic position of the
hand brake lever (FE US) . . .. . .. . .. . . .. . .. . 135
16.5
Adjusting free travel of hand brake
lever (FE EU/ AU) ............................... 135
16.6
Checking the front brake fluid
level ................................................... 136
16.7
Adding front brake fluid .................... 136
16.8
Changing the front brake fluid .......... 137
16.9
Checking the rear brake linings ........ 139
16.10 Changing the rear brake linings ........ 139
16.11 Checking the free travel of foot
brake lever . . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . .. . . 142
16.12 Adjusting the basic position of the
foot brake lever................................. 143
16.13 Checking the rear brake fluid level ... 143
16.14 Adding rear brake fluid ..................... 144
16.15 Changing the rear brake fluid ........... 145
17 LIGHTING SYSTEM, INSTRUMENTS ........... 148
17 .1
Adjusting the combination
instrument......................................... 148
17.2
Adjusting the kilometers or miles ...... 149
17.3
Adjusting the clock ........................... 149
17.4
Setting the wheel circumference ...... 150
17 .5
Adjusting the service display ............ 150
17.6
Checking the headlight setting ......... 151
17.7
Adjusting the headlight range ........... 151
18 ENGINE ......................................................... 152
4
18.1
18.2
18.3
18.3.1
18.3.2
18.3.3
18.3.4
18.3.5
18.3.6
18.3.7
18.3.8
18.3.9
18.3.10
18.3.11
18.3.12
18.3.13
Removing the engine ........................ 152
Installing the engine .......................... 156
Engine disassembly .......................... 162
Preparations................................. 162
Removing the clutch push rod ..... 162
Removing the spacer ................... 162
Draining the engine oil. ................. 162
Removing the oil filter ................... 163
Removing the spark plug ............. 163
Removing the valve cover ............ 164
Removing the alternator cover ..... 164
Removing the torque limiter ......... 165
Positioning the engine at
ignition top dead center ............... 165
Removing the timing chain
tensioner....................................... 165
Removing the camshafts .............. 166
Removing the cylinder head ......... 166
18.3.14
Removing the piston .................... 167
18.3.15
Removing the starter drive ........... 167
18.3.16
Removing the suction pump ........ 169
18.3.17
Removing the water pump
wheel ............................................ 170
18.3.18
Removing the clutch cover ........... 170
18.3.19
Removing the clutch discs ........... 170
18.3.20
Removing the clutch basket ......... 171
18.3.21
Removing the shift shaft ............... 172
18.3.22
Removing the shift drum
locating unit.. ................................ 172
18.3.23
Removing the locking lever .......... 173
18.3.24
Removing the force pump ............ 173
18.3.25
Removing the primary gear .......... 17 4
18.3.26
Removing the timing chain ........... 17 4
18.3.27
Removing the spacer ................... 174
18.3.28
Removing the left section of the
engine case .................................. 175
18.3.29
Removing the shift rails ................ 175
18.3.30
Removing the shift drum .............. 176
18.3.31
Removing the shift forks .............. 176
18.3.32
Removing the transmission
shafts ............................................ 176
18.3.33
Removing the crankshaft ............. 177
18.4
Working on individual parts .............. 177
18.4.1
Work on the right section of the
engine case .................................. 177
18.4.2
Work on the left section of the
18.4.3
18.4.4
18.4.5
18.4.6
18.4.7
18.4.8
18.4.9
18.4.10
18.4.11
18.4.12
18.4.13
18.4.14
18.4.15
engine case .................................. 179
Work on the clutch cover . . .. . .. . .. . . . 180
Checking the oil pressure
regulator valve .............................. 182
Checking the lubrication
system .......................................... 183
Removing the crankshaft
bearing inner race ......................... 183
Installing the crankshaft bearing
inner race ...................................... 184
Changing the connecting rod,
conrod bearing, and crank pin ..... 184
Checking the crankshaft run-out
at the bearing pin ......................... 186
Measuring the crankshaft end
play ............................................... 186
Removing the drive wheel of the
balancer shaft ............................... 187
Installing the drive wheel of the
balancer shaft ............................... 187
Cylinder - Nikasil
®
coating ............ 187
Checking/measuring the
cylinder ......................................... 188
Checking/measuring the piston ... 188
