Table of Contents
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INDEX
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cylinder -
Nikasil
coating . . . . . . . . . . . . . . . . . . . 152
cylinder head, checking . . . . . . . . . . . . . . . . . . . . . 159
cylinder, checking/measuring
freewheel, checking
freewheel, installing . . . . . . . . . . . . . . . . . . . . . . . . 171
freewheel, removing . . . . . . . . . . . . . . . . . . . . . . . . 171
left engine case section
main shaft, assembling . . . . . . . . . . . . . . . . . . . . . . 168
main shaft, disassembling . . . . . . . . . . . . . . . . . . . . 166
oil pressure regulator valve, installing
oil pressure regulator valve, removing . . . . . . . . . . . . 147
oil pumps, checking . . . . . . . . . . . . . . . . . . . . . . . . 154
piston, checking/measuring
piston/cylinder, determining the mounting clearance . 154
right engine case section
rocker arm shafts, checking
rocker arm, removing ...................... .
shift mechanism, checking .................. .
shift shaft, preassembling ................... .
spring length of oil pressure regulator valve, checking
starter drive, checking . . . . . . . . . . . . . . . . . . . . . . 170
timing assembly, checking . . . . . . . . . . . . . . . . . . . 156
timing chain sprocket, installing . . . . . . . . . . . . . . . . 150
timing chain sprocket, removing
transmission, checking . . . . . . . . . . . . . . . . . . . . . . 167
valve spring seat, checking . . . . . . . . . . . . . . . . . . . 159
valve springs, checking
valves, checking . . . . . . . . . . . . . . . . . . . . . . . . . . 158
water pump, installing . . . . . . . . . . . . . . . . . . . . . . 149
water pump, removing . . . . . . . . . . . . . . . . . . . . . . 148
Engine - work on the individual parts
piston ring end gap, checking . . . . . . . . . . . . . . . . . 153
rocker arm, installing . . . . . . . . . . . . . . . . . . . . . . . 161
valves, installing . . . . . . . . . . . . . . . . . . . . . . . . . . 160
valves, removing . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Engine assembly
alternator cover, installing . . . . . . . . . . . . . . . . . . . . 185
camshaft, installing . . . . . . . . . . . . . . . . . . . . . . . . 183
clutch cover, installing . . . . . . . . . . . . . . . . . . . . . . 178
clutch discs, installing . . . . . . . . . . . . . . . . . . . . . . 177
clutch push rod, installing . . . . . . . . . . . . . . . . . . . . 186
cylinder head, installing
engine, removing from engine assembly stand
force pump, installing . . . . . . . . . . . . . . . . . . . . . . . 17 4
freewheel gear, installing . . . . . . . . . . . . . . . . . . . . . 17 4
ignition pulse generator, installing
left engine case, installing . . . . . . . . . . . . . . . . . . . . 173
locking lever, installing . . . . . . . . . . . . . . . . . . . . . . 175
oil filter, installing . . . . . . . . . . . . . . . . . . . . . . . . . . 186
oil screens, installing . . . . . . . . . . . . . . . . . . . . . . . 186
outer clutch hub, installing . . . . . . . . . . . . . . . . . . . 176
piston, installing . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
primary gear, installing ...................... 174
rotor, installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
shift drum locating unit, installing . . . . . . . . . . . . . . . 176
shift drum, installing
shift forks, installing . . . . . . . . . . . . . . . . . . . . . . . . 172
shift rails, installing . . . . . . . . . . . . . . . . . . . . . . . . . 173
shift shaft, installing . . . . . . . . . . . . . . . . . . . . . . . . 176
spark plug, installing
starter idler gear, installing
152
starter motor, installing . . . . . . . . . . . . . . . . . . . . . . 186
170
suction pump, installing . . . . . . . . . . . . . . . . . . . . . 179
timing chain tensioner, installing . . . . . . . . . . . . . . . 183
timing chain, installing . . . . . . . . . . . . . . . . . . . . . . 180
146
torque limiter, installing . . . . . . . . . . . . . . . . . . . . . . 176
transmission shafts, installing . . . . . . . . . . . . . . . . . 172
valve clearance, adjusting . . . . . . . . . . . . . . . . . . . . 184
148
valve cover, installing . . . . . . . . . . . . . . . . . . . . . . . 185
water pump cover, installing
Engine disassembly
153
alternator cover, removing
camshaft, removing . . . . . . . . . . . . . . . . . . . . . . . . 134
144
clutch cover, removing . . . . . . . . . . . . . . . . . . . . . . 138
160
clutch discs, removing . . . . . . . . . . . . . . . . . . . . . . 138
157
clutch push rod, removing . . . . . . . . . . . . . . . . . . . . 132
164
crankshaft, removing . . . . . . . . . . . . . . . . . . . . . . . 144
165
cylinder head, removing . . . . . . . . . . . . . . . . . . . . . 135
147
engine oil, draining ......................... 131
engine, positioning at ignition top dead center . . . . . . 133
force pump, removing
freewheel gear, removing . . . . . . . . . . . . . . . . . . . . 142
150
ignition pulse generator, removing
left engine case section, removing . . . . . . . . . . . . . . 142
locking lever, removing . . . . . . . . . . . . . . . . . . . . . . 140
159
oil filter, removing
outer clutch hub, removing . . . . . . . . . . . . . . . . . . . 139
piston, removing . . . . . . . . . . . . . . . . . . . . . . . . . . 135
preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
primary gear, removing . . . . . . . . . . . . . . . . . . . . . . 142
rotor, removing . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
shift drum locating unit, removing . . . . . . . . . . . . . . 140
shift drum, removing
shift forks, removing
shift rails, removing
shift shaft, removing
spark plug, removing . . . . . . . . . . . . . . . . . . . . . . . 132
starter idler gear, removing . . . . . . . . . . . . . . . . . . . 140
starter motor, removing
suction pump, removing . . . . . . . . . . . . . . . . . . . . . 137
timing chain tensioner, removing . . . . . . . . . . . . . . . 134
182
timing chain, removing . . . . . . . . . . . . . . . . . . . . . . 136
187
torque limiter, removing . . . . . . . . . . . . . . . . . . . . . 140
transmission shafts, removing . . . . . . . . . . . . . . . . . 143
valve cover, removing . . . . . . . . . . . . . . . . . . . . . . . 133
180
water pump cover, removing . . . . . . . . . . . . . . . . . . 137
Engine number
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Engine oil
adding ................................. 198
changing
Engine oil level
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Engine oil pressure
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
173
Engine sprocket
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
243
185
176
179
133
141
137
132
143
143
143
140
132
196
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