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I
I
Cylinder
- Coat both sides of the base gasket with a thin coat of RTV silicone sealer, especially around the water passages. Install
the base gasket onto the base of the cylinder and line it up with the casting. Slide the cylinder into position over the cylinder studs,
then lower it onto the studs. When cylinder nears the piston, prop the cylinder in position over the piston. Make sure the piston ring
gap is centered over the alignment pin in the ring groove at the left rear of the piston. Using your thumb and forefinger, reach around
the piston and compress the piston ring into its groove on both sides, making sure the ring gap is still centered over the alignment
pin in the ring groove. Line the piston up with the cylinder bore and lower the cylinder and/or raise the piston until the top of the
piston and the piston ring enter the cylinder. If the piston won’t slide into the cylinder, do not force it. Remove the piston and try
again. The ring must be compressed to enter the base of the cylinder, and the piston ring gap must line up with the alignment pin in
the ring groove. Insert the piston into the cylinder as far as possible, then lower the cylinder onto the cases. See photo III-19.
Head
- Using a little premix oil, stick the large o-ring into its groove in the underside of the combustion chamber. Place 4 small o-
rings over cylinder studs and against top of cylinder. Making sure the o-rings stay in place, slide the combustion chamber over the
cylinder studs and down onto the cylinder. Install the large o-ring around the spark plug hole and the 4 smaller o-rings on the cylin-
der studs. Install the large o-ring gasket into the groove of the cylinder head and install it on top of the combustion chamber. Thread
the 4 cylinder nuts onto the cylinder studs finger tight. Check to make sure the cylinder fits the cases tightly and the cylinder head
fits the cylinder tightly. Torque the cylinder nuts in 3 stages using a criss cross pattern each time. Tighten using a good quality torque
wrench to 3 ft/lbs, then 6 ft/lbs, finally to 10 ft/lbs. Install spark plug and torque to 20 ft/lbs.
Reinstall radiators in reverse order. Use a pair of pliers modified as per illustration III-20 or a CV joint clamp plier (available at
autopart stores) to snap the hose clamps closed again. Bolt exhaust extension in place and torque bolts to
10 Nm
. Guide expansion
pipe through frame and insert rear of pipe into muffler. Lubricate o-ring on front of pipe, then insert front of pipe into exhaust exten-
sion and twist pipe back and forth while pushing to fully install pipe.
Hook spring(s) onto exhaust extension, then hook onto pipe. Install lock
nut on rubber mount and snug — do not overtighten. Replace fuel tank
and rear seat. Do not tighten tank or seat screw excessively. Add motorcy-
cle type coolant to radiator until full. Put bike on stand with rear wheel off
ground. Start bike and rev just enough to circulate coolant. Recheck
coolant level and add coolant as needed. Follow instructions for break-in
(Section I-4) to maximize piston and ring life.
16.2 Crankcase & Transmission
Disassembly
Remove engine from frame
- Remove seat and fuel tank. See section III-
16.1 for removal of the following items. Remove exhaust pipe and exhaust
extension. Remove carburetor from airbox & engine boot and set off to
side. Drain coolant and remove left radiator. Disconnect radiator hoses
from water pump cover. Remove hose and water outlet from top of cylin-
der head. Drain transmission oil. Loosen chain, remove sprocket guard,
remove external snap ring and remove front sprocket from counter shaft.
Remove vent hose from fitting on engine. Remove brake pedal. Remove
ignition cover. Make an index mark on stator and case with
magic marker or pen to help with retiming the motor on reassem-
bly. Remove spark plug & install piston stop tool. Use puller to
remove flywheel - see section III-20. Remove three phillips head
screws and remove stator from engine, making sure to remove
wiring grommet from case so it does not pull on stator wires. Set
stator to side. Remove stator mounting plate using 3mm allen
wrench. See photo III-21.
Remove kickstarter and clutch cover. Using piston stop tool,
remove clutch nut and remove clutch assembly from crankshaft,
see section III-17. Remove front motor bolt, then remove rear
swingarm pivot bolt. Pull engine upward and forwards to disen-
gage from swingarm, and remove from frame on left side.
Remove cylinder head, cylinder, piston and reed valve assem-
bly - See sections III-15 and III-16.1
Remove 11 case bolts from left side of engine using 5mm allen
wrench, including 4 under stator mounting plate. See photo III-
22. Fit case splitting tool over crank shaft on right (clutch) side
of engine as shown. Install bolts to secure tool to engine case.
Make sure to remove 4 case bolts beneath stator mounting plate.
Remove stator plate to expose 4 case bolts
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