TABLE OF CONTENTS
15. 7
Checking the capacitor ..................... 133
15.8
Checking the starter relay ................. 134
16 BRAKE SYSTEM ........................................... 136
16.1
16.2
16.3
16.4
16.5
16.6
16.7
16.8
16.9
Checking the front brake linings ....... 136
Changing the front brake linings ....... 136
Checking the free travel of the
hand brake lever . . .. . . .. . .. . .. . .. . .. . .. . .. . .. . . 138
Adjusting the basic position of the
hand brake lever . . .. . . .. . .. . .. . .. . .. . .. . .. . .. . . 138
Checking the brake fluid level of
the front brake . . .. . .. . . .. . .. . .. . .. . .. . .. . .. . .. . . 139
Adding front brake fluid .................... 140
Changing the front brake fluid .......... 141
Checking the brake linings of the
rear brake.......................................... 143
Changing the rear brake linings ........ 143
16.10 Checking the free travel of foot
brake lever . . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . .. . . 145
16.11 Adjusting the basic position of the
foot brake lever................................. 146
16.12 Checking the rear brake fluid level ... 146
16.13 Adding rear brake fluid ..................... 147
16.14 Changing the rear brake fluid ........... 148
17 ENGINE ......................................................... 150
4
17.1
Removing the engine ........................ 150
17.2
Installing the engine .......................... 157
17 .3
Engine disassembly .......................... 165
17 .3.1
Preparations ................................. 165
17 .3.2
Removing the clutch push rod ..... 165
17 .3.3
Draining the engine oil. ................. 165
17 .3.4
Removing the oil filter ................... 166
17 .3.5
Removing the gear position
sensor ........................................... 167
17.3.6
Removing the spark plug ............. 167
17 .3. 7
Removing the valve cover ............ 167
17 .3.8
Removing the starter motor ......... 168
17 .3.9
Positioning the engine at
ignition top dead center ............... 169
17 .3.10
Removing the timing chain
tensioner ....................................... 169
17 .3.11
Removing the camshafts .............. 170
17.3.12
Removing the cylinder head ......... 170
17.3.13
Removing the piston .................... 171
17.3.14
Removing the rotor ....................... 171
17.3.15
Removing the starter drive ........... 172
17 .3.16
Removing the suction pump ........ 172
17 .3.17
Removing the water pump
impeller ......................................... 173
17.3.18
Removing the clutch cover ........... 174
17.3.19
Removing the clutch discs ........... 174
17.3.20
Removing the clutch basket ......... 175
17.3.21
Removing the primary gear .......... 176
17.3.22
Removing the timing chain ........... 176
17.3.23
Removing the force pump ............ 176
17.3.24
Removing the locking lever .......... 177
17.3.25
Removing the shift drum
locating unit.. ................................ 178
17.3.26
Removing the shift shaft ............... 178
17.3.27
Removing the spacer ................... 178
17.3.28
Removing the left engine case ..... 178
17.3.29
Removing the shift rails ................ 179
17.3.30
Removing the shift drum .............. 179
17.3.31
Removing the shift forks .............. 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
the engine case ............................ 181
17.4.2
Work on the left section of the
engine case .................................. 183
17.4.3
Work on the clutch cover ............. 184
17.4.4
Checking the oil pressure
regulator valve .............................. 186
17.4.5
Checking the lubrication
system .......................................... 187
17.4.6
Removing the crankshaft
bearing inner race ......................... 187
17.4.7
Changing the connecting rod,
conrod bearing, and crank pin ..... 188
17.4.8
Checking the crankshaft run-out
at the bearing pin ......................... 190
17.4.9
Installing the crankshaft bearing
inner race ...................................... 190
17.4.10
Measuring the crankshaft end
play ............................................... 191
17.4.11
Removing the drive wheel of the
balancer shaft ............................... 191
17.4.12
Installing the drive wheel of the
balancer shaft ............................... 192
17.4.13
Cylinder - Nikasil
®
coating ............ 192
17.4.14
Checking/measuring the
cylinder ......................................... 192
17.4.15
Checking/measuring the piston ... 193
17.4.16
Measuring the piston/cylinder
mounting clearance...................... 194
17.4.17
Checking the piston ring end
gap ............................................... 194
17.4.18
Changing the camshaft
bearing . . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . .. . . . 195
17.4.19
Checking the camshafts ............... 195
