TABLE OF CONTENTS
4
17.4.30 Checking the clutch .................................. 138
17.4.31 Preassembling the antihopping clutch......... 140
17.4.32 Checking shift mechanism......................... 141
17.4.33 Preassembling shift shaft .......................... 141
17.4.34 Disassembling the main shaft .................... 142
17.4.35 Dismantling countershaft........................... 142
17.4.36 Checking the transmission ......................... 143
17.4.37 Assembling the main shaft......................... 144
17.4.38 Assembling countershaft ........................... 145
17.4.39 Checking the starter drive .......................... 146
17.4.40 Removing freewheel .................................. 146
17.4.41 Checking freewheel ................................... 147
17.4.42 Installing freewheel................................... 147
17.5
Engine assembly........................................... 148
17.5.1
Installing transmission shafts..................... 148
17.5.2
Installing crankshaft and balancer shaft...... 149
17.5.3
Installing left engine case.......................... 150
17.5.4
Installing oil pumps .................................. 150
17.5.5
Installing locking lever .............................. 151
17.5.6
Installing shift drum locating ..................... 151
17.5.7
Installing shift shaft .................................. 151
17.5.8
Installing starter drive ............................... 151
17.5.9
Installing primary gear............................... 152
17.5.10 clutch cage, installing ............................... 152
17.5.11 Installing crankshaft position sensor ........... 153
17.5.12 Installing timing chain and timing chain
sprocket................................................... 154
17.5.13 Installing timing chain rails ....................... 154
17.5.14 Installing rotor.......................................... 154
17.5.15 Adjusting crankshaft position sensor
distance................................................... 155
17.5.16 Setting engine to top dead center............... 155
17.5.17 Installing piston........................................ 155
17.5.18 Installing cylinder head ............................. 157
17.5.19 Installing camshafts.................................. 157
17.5.20 Installing timing chain tensioner ................ 158
17.5.21 Checking valve clearance........................... 158
17.5.22 Adjusting valve clearance .......................... 159
17.5.23 Installing spark plug.................................. 160
17.5.24 Installing spacer and spring ....................... 160
17.5.25 Installing clutch cover ............................... 160
17.5.26 Mounting water pump cover ....................... 160
17.5.27 Installing thermostat ................................. 161
17.5.28 Installing the oil filter................................ 161
17.5.29 Installing gear position sensor .................... 161
17.5.30 Installing the spacer.................................. 162
17.5.31 Installing oil screens ................................. 162
17.5.32 Installing alternator cover .......................... 163
17.5.33 Installing the starter motor......................... 163
17.5.34 Installing valve cover................................. 164
17.5.35 Removing the engine from the engine
assembly stand......................................... 164
18 CLUTCH.................................................................. 165
18.1
Checking/rectifying the fluid level of the
hydraulic clutch............................................ 165
18.2
Changing the hydraulic clutch fluid ................ 165
19 WATER PUMP, COOLING SYSTEM ............................ 166
19.1
Draining the coolant...................................... 166
19.2
Filling/bleeding the cooling system ................. 166
19.3
Checking the antifreeze and coolant level ........ 167
19.4
Checking the coolant level ............................. 168
20 LUBRICATION SYSTEM............................................ 169
20.1
Oil circuit..................................................... 169
20.2
Checking the engine oil level.......................... 169
20.3
Checking the engine oil pressure .................... 170
20.4
Changing the engine oil and filter, cleaning
the oil screens .............................................. 171
20.5
Draining the engine oil .................................. 171
20.6
Removing the oil filter ................................... 172
20.7
Installing the oil filter.................................... 172
20.8
Cleaning the oil screens................................. 173
20.9
Filling up with engine oil ............................... 174
20.10 Adding engine oil.......................................... 174
21 IGNITION SYSTEM................................................... 175
21.1
Alternator - checking the stator winding .......... 175
21.2
Checking the spark plug connector ................. 175
21.3
Ignition coil - checking the secondary
winding........................................................ 176
22 TECHNICAL DATA.................................................... 177
22.1
Engine ......................................................... 177
22.2
Engine tolerance, wear limits ......................... 177
22.3
Engine tightening torques .............................. 179
22.4
Capacities .................................................... 180
22.4.1
Engine oil ................................................ 180
22.4.2
Coolant .................................................... 180
22.4.3
Fuel ........................................................ 180
22.5
Chassis ........................................................ 180
22.6
Electrical system........................................... 181
22.7
Tires ............................................................ 181
22.8
Fork............................................................. 182
22.9
Shock absorber ............................................. 182
22.10 Chassis tightening torques ............................. 183
23 CLEANING/PROTECTIVE TREATMENT....................... 185
23.1
Cleaning the motorcycle ................................ 185
23.2
Checks and maintenance steps for winter
operation...................................................... 186
24 STORAGE................................................................ 187
24.1
Storage ........................................................ 187
24.2
Preparing for use after storage........................ 187
25 SERVICE SCHEDULE ............................................... 188
25.1
Service schedule........................................... 188
26 WIRING DIAGRAM ................................................... 190
26.1
Page 01 of 10 .............................................. 190
26.2
Page 02 of 10 .............................................. 192
26.3
Page 03 of 10 .............................................. 194
26.4
Page 04 of 10 .............................................. 196
26.5
Page 05 of 10 .............................................. 198
26.6
Page 06 of 10 .............................................. 200
26.7
Page 07 of 10 .............................................. 202
26.8
Page 08 of 10 .............................................. 204
26.9
Page 09 of 10 .............................................. 206
26.10 Page 10 of 10 .............................................. 208
27 SUBSTANCES ......................................................... 210
28 AUXILIARY SUBSTANCES ........................................ 212
29 SPECIAL TOOLS ...................................................... 214
30 STANDARDS ........................................................... 227
INDEX ............................................................................ 228
