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rocker arm shafts, checking . . . . . . . . . . . 207
shift shaft, preassembling . . . . . . . . . . . . . 217
starter drive, checking . . . . . . . . . . . . . . . 223
timing assembly, checking . . . . . . . . . . . . 202
timing chain sprocket, removing . . . . . . . . 192
valve spring seat, checking . . . . . . . . . . . . 206
valve springs, checking . . . . . . . . . . . . . . 206
Engine - work on the individual parts
camshaft bearing, changing . . . . . . . . . . . 204
connecting rod, conrod bearing, and crank
pin, changing . . . . . . . . . . . . . . . . . . . . . 194
piston ring end gap, checking . . . . . . . . . . 199
piston, checking/measuring . . . . . . . . . . . 198
valves, checking . . . . . . . . . . . . . . . . . . . 205
valves, installing
water pump, removing .............. .
Engine - working on the individual parts
Checking the cylinder head ........... .
clutch, checking
countershaft, assembling . . . . . . . . . . . . . 222
countershaft, disassembling . . . . . . . . . . . 219
crankshaft bearing inner race, installing
crankshaft bearing inner race, removing . . . 193
crankshaft end play, measuring . . . . . . . . . 196
crankshaft seal ring in the clutch cover,
changing . . . . . . . . . . . . . . . . . . . . . . . . 190
®
cylinder -
Nikasil
- coating . . . . . . . . . . . 197
cylinder, checking/measuring . . . . . . . . . . 197
disassembling the antihopping clutch . . . . . 209
freewheel, checking . . . . . . . . . . . . . . . . . 224
freewheel, installing . . . . . . . . . . . . . . . . . 224
main shaft, assembling . . . . . . . . . . . . . . . 221
main shaft, disassembling . . . . . . . . . . . . . 218
oil pressure control valve, installing
oil pressure control valve, removing . . . . . . 189
preassembling the antihopping clutch
removing the freewheel . . . . . . . . . . . . . . . 224
rocker arm, installing ................ 208
rocker arm, removing . . . . . . . . . . . . . . . . 203
section of the engine case, left . . . . . . . . . 188
section of the engine case, right . . . . . . . . 186
shift mechanism, checking . . . . . . . . . . . . 216
spring length of the oil pressure control valve,
checking . . . . . . . . . . . . . . . . . . . . . . . . . 190
timing chain sprocket, installing . . . . . . . . . 192
transmission, checking . . . . . . . . . . . . . . . 219
valves, removing . . . . . . . . . . . . . . . . . . . 203
water pump, installing . . . . . . . . . . . . . . . 191
Engine assembly
alternator cover, installing ............. 242
camshaft, installing . . . . . . . . . . . . . . . . . 240
clutch basket, installing . . . . . . . . . . . . . . 231
clutch cover, installing . . . . . . . . . . . . . . . 233
clutch discs, installing . . . . . . . . . . . . . . . 232
clutch push rod, installing . . . . . . . . . . . . . 244
crankshaft, installing
cylinder head, installing
engine, removing from the engine assembly
stand ........................... 245
force pump, installing . . . . . . . . . . . . . . . . 229
freewheel gear, installing . . . . . . . . . . . . . . 228
gear position sensor, installing . . . . . . . . . . 235
left engine case, installing . . . . . . . . . . . . . 227
locking lever, installing . . . . . . . . . . . . . . . 229
oil filter, installing . . . . . . . . . . . . . . . . . . . 243
oil screens, installing ............... .
207
piston, installing ................... .
190
primary gear wheel, installing ......... .
rotor, installing .................... .
206
shift drum locating unit, installing . . . . . . . . 229
214
shift drum, installing . . . . . . . . . . . . . . . . . 227
shift forks, installing . . . . . . . . . . . . . . . . . 226
shift rails, installing
193
shift shaft, installing
spark plug, installing
starter idler gear, installing . . . . . . . . . . . . 230
starter motor, installing ............... 243
suction pump, installing . . . . . . . . . . . . . . 235
timing chain tensioner, installing . . . . . . . . 240
timing chain, installing . . . . . . . . . . . . . . . 236
torque limiter, installing . . . . . . . . . . . . . . . 231
transmission shafts, installing . . . . . . . . . . 226
valve clearance, adjusting . . . . . . . . . . . . . 241
valve clearance, checking . . . . . . . . . . . . . 241
valve cover, installing . . . . . . . . . . . . . . . . 242
190
water pump cover, installing
Engine disassembly
211
alternator cover, removing
camshaft, removing . . . . . . . . . . . . . . . . . 175
clutch basket, removing . . . . . . . . . . . . . . 180
clutch cover, removing . . . . . . . . . . . . . . . 179
clutch discs, removing . . . . . . . . . . . . . . . 179
clutch push rod, removing . . . . . . . . . . . . . 171
crankshaft, removing . . . . . . . . . . . . . . . . 186
cylinder head, removing . . . . . . . . . . . . . . 175
engine oil, draining . . . . . . . . . . . . . . . . . . 171
engine, positioning at ignition top dead center 17 4
force pump, removing . . . . . . . . . . . . . . . 181
freewheel gear, removing . . . . . . . . . . . . . 183
gear position sensor, removing . . . . . . . . . 178
left engine case section, removing . . . . . . . 184
locking lever, removing . . . . . . . . . . . . . . . 183
INDEX
225
239
244
237
228
236
227
229
243
234
173
331
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