CONTENTS
Page 3
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Removal of the rear caliper and the brake pads................................................................................................................ 21
Removal of the shock absorber.......................................................................................................................................... 22
Removal of the shock absorber pivot ................................................................................................................................ 23
Removal of the suspension arm ......................................................................................................................................... 24
Suspension arm pre- assembled (mudguard, chain guard, guide and tensioners fitted) ................................................. 25
MISCELLANEOUS OPERATIONS .......................................................................................................... 26
Removal of the rear mudflap.............................................................................................................................................. 26
Removal of the rear light assembly................................................................................................................................... 26
Removal of the number plate plinth .................................................................................................................................. 26
Removal of the instrument panel ....................................................................................................................................... 27
Removal of the windshield................................................................................................................................................. 27
Removal of a front direction indicator .............................................................................................................................. 27
Removal of a rear direction indicator................................................................................................................................ 27
Removal of the steering lock.............................................................................................................................................. 28
Removal of the throttle grip and oil pump ........................................................................................................................ 29
Removal of the oil tank ...................................................................................................................................................... 29
Removal of the air filter foam............................................................................................................................................ 30
Removal of the air filter box .............................................................................................................................................. 30
Removal of the exhaust
Operation 11
............................................................................................................................. 30
Removal of the carburettor
Operation 12
........................................................................................................................ 31
Removal of the valves ........................................................................................................................................................ 31
ELECTRICITY........................................................................................................................................... 32
Removal of the battery........................................................................................................................................................ 32
Removal of the starter motor relay.................................................................................................................................... 32
Removal of the voltage regulator....................................................................................................................................... 32
Removal of a LH or RH control cluster ............................................................................................................................ 32
Removal of the ignition module......................................................................................................................................... 33
Removal of the horn ........................................................................................................................................................... 33
Removal of the rear wiring harness................................................................................................................................... 33
Removal of the main harness............................................................................................................................................. 35
Refitting the main harness.................................................................................................................................................. 36
WORK ON THE ENGINE WITHOUT REMOVING THE ENGINE...................................................... 37
Removal of the cylinder head/ cylinder/ piston .................................................................................................................. 37
Removal of the oil pump.................................................................................................................................................... 38
Removal of the rotor and the magneto flywheel armature............................................................................................... 39
Removal of the gearbox output sprocket........................................................................................................................... 40
Removal of the neutral s witch............................................................................................................................................ 40
Removal of the starter motor.............................................................................................................................................. 41
COOLING.................................................................................................................................................... 42
Removal of the cylinder head/ radiator hose...................................................................................................................... 42
Removal of the expansion tank and the expansion tank/ radiator hose............................................................................ 42
Removal of the radiator...................................................................................................................................................... 42
Removal of the engine temperature sensor ....................................................................................................................... 43
MOTOR....................................................................................................................................................... 44
Removal of the engine........................................................................................................................................................ 44
Refitting the engine to the frame ....................................................................................................................................... 46
FRAME........................................................................................................................................................ 47
Removal of the frame ......................................................................................................................................................... 47