TABLE OF CONTENTS
15.9
Checking the capacitor ..................... 141
15.10 Checking the starter relay ................. 142
16 BRAKE SYSTEM ........................................... 144
16.1
16.2
16.3
16.4
16.5
16.6
16.7
16.8
16.9
Checking the front brake linings ....... 144
Changing the front brake linings ....... 144
Adjusting the basic position of the
hand brake lever . . .. . . .. . .. . .. . .. . .. . .. . .. . .. . . 146
Checking the front brake fluid
level ................................................... 147
Adding front brake fluid .................... 147
Changing the front brake fluid .......... 148
Checking the brake linings of the
rear brake.......................................... 1 50
Changing the rear brake linings ........ 150
Checking the free travel of foot
brake lever . . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . .. . . 152
16.10 Adjusting the basic position of the
foot brake lever................................. 153
16.11 Checking the rear brake fluid level ... 153
16.12 Adding rear brake fluid ..................... 154
16.13 Changing the rear brake fluid ........... 155
17 ENGINE ......................................................... 158
4
17.1
Removing the engine ........................ 158
17.2
Installing the engine .......................... 165
17 .3
Engine disassembly .......................... 173
17 .3.1
Preparations ................................. 173
17 .3.2
Draining the engine oil. ................. 173
17.3.3
Removing the clutch push rod ..... 174
17 .3.4
Removing the oil filter ................... 17 4
17 .3.5
Removing the starter motor ......... 175
17.3.6
Removing the spark plug ............. 175
17 .3. 7
Removing the valve cover ............ 175
17 .3.8
Removing the alternator cover ..... 175
17 .3.9
Positioning the engine at
ignition top dead center ............... 176
17.3.10
Removing the timing chain
tensioner ....................................... 176
17 .3.11
Removing the camshaft ............... 177
17.3.12
Removing the cylinder head ......... 177
17.3.13
Removing the piston .................... 178
17.3.14
Removing the rotor ....................... 178
17.3.15
Removing the timing chain ........... 179
17 .3.16
Removing the suction pump ........ 179
17 .3.17
Removing the gear position
sensor ........................................... 180
17.3.18
Removing the water pump
cover ............................................. 180
17.3.19
Removing the clutch cover ........... 181
17.3.20
Removing the clutch discs ........... 181
17 .3.21
Removing the clutch basket ......... 182
17.3.22
Removing the torque limiter ......... 183
17.3.23
Removing the starter idler gear .... 183
17.3.24
Removing the force pump ............ 183
17.3.25
Removing the shift shaft ............... 184
17.3.26
Removing the shift drum
locating unit.. ................................ 185
17.3.27
Removing the locking lever .......... 185
17.3.28
primary gear wheel, removing ...... 185
17.3.29
Removing the freewheel gear ....... 185
17.3.30
Removing the left engine case
section.......................................... 186
17.3.31
Removing the shift rails ................ 187
17.3.32
Removing the shift drum .............. 187
17.3.33
Removing the shift forks .............. 187
17.3.34
Removing the transmission
shafts ............................................ 187
17.3.35
Removing the crankshaft ............. 188
17.4
Working on individual parts .............. 188
17.4.1
Working on the right section of
the engine case ............................ 188
17.4.2
Working on the left section of
the engine case ............................ 190
17.4.3
oil pressure control valve,
removing ....................................... 191
17.4.4
spring length of the oil pressure
control valve, checking ................. 192
17.4.5
oil pressure control valve,
installing ....................................... 192
17.4.6
crankshaft seal ring in the
clutch cover, changing ................. 192
17.4. 7
Removing the water pump ........... 192
17.4.8
Installing the water pump ............. 193
17.4.9
Removing the timing chain
sprocket .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . .. 194
17.4.10
Installing the timing chain
sprocket .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . .. 194
17.4.11
Removing the crankshaft
bearing inner race ......................... 195
17.4.12
Installing the crankshaft bearing
inner race ...................................... 195
17.4.13
Changing the connecting rod,
conrod bearing, and crank pin ..... 196
17.4.14
Checking crankshaft run-out at
bearing pin ................................... 198
17.4.15
Measuring the crankshaft end
play ............................................... 198
17.4.16
Cylinder - Nikasil
®
- coating ......... 199
17.4.17
Checking/measuring the
cylinder ......................................... 199
17.4.18
Checking/measuring the piston ... 200
17.4.19
Checking the piston ring end
gap ............................................... 201
