Table of Contents
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INDEX
checking the lubrication system . . . . . . . . . . . . . . . . . 82
checking the oil pumps for wear . . . . . . . . . . . . . . . . . 82
checking the piston ring end gap
checking the shift mechanism
checking the spring length of the oil pressure regulator
valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
checking the timing assembly
checking the transmission . . . . . . . . . . . . . . . . . . . . . 93
checking the valve springs . . . . . . . . . . . . . . . . . . . . . 87
checking the valves . . . . . . . . . . . . . . . . . . . . . . . . . . 87
checking/measuring the cylinder . . . . . . . . . . . . . . . . . 80
checking/measuring the piston . . . . . . . . . . . . . . . . . . 81
®
Cylinder - Nikasil
coating . . . . . . . . . . . . . . . . . . . . . 80
disassembling the autodecompressor . . . . . . . . . . . . . . 83
dismantling the countershaft . . . . . . . . . . . . . . . . . . . 92
dismantling the main shaft
fitting the crankshaft seal ring into the clutch cover . . . . 76
installing the free-wheel
installing the oil pressure regulator valve . . . . . . . . . . . 75
installing the rocker arm
installing the timing chain sprocket . . . . . . . . . . . . . . . 78
installing the water pump
installing valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
left engine case section . . . . . . . . . . . . . . . . . . . . . . . 73
preassembling the shift shaft . . . . . . . . . . . . . . . . . . . 91
preparing the timing chain tensioner for installation
removing the crankshaft seal ring in the clutch cover . . . 76
removing the free-wheel
removing the oil pressure regulator valve
removing the rocker arm
removing the timing chain sprocket . . . . . . . . . . . . . . . 78
removing the valves
. . . . . . . . . . . . . . . . . . . . . . . . . 85
removing the water pump
replacing the camshaft bearing . . . . . . . . . . . . . . . . . . 86
right engine case section . . . . . . . . . . . . . . . . . . . . . . 72
Engine assembly
adjusting the valve clearance . . . . . . . . . . . . . . . . . . 109
checking the valve clearance . . . . . . . . . . . . . . . . . . 109
cleaning the gear oil screen . . . . . . . . . . . . . . . . . . . . 59
Filling up with engine oil . . . . . . . . . . . . . . . . . . . . . 111
Filling up with gear oil . . . . . . . . . . . . . . . . . . . . . . . 112
installing the balance weight
installing the balancer shaft . . . . . . . . . . . . . . . . . . . 101
installing the camshaft . . . . . . . . . . . . . . . . . . . . . . 108
installing the clutch cover . . . . . . . . . . . . . . . . . . . . 102
installing the clutch discs
installing the crankshaft
installing the cylinder head
installing the generator cover . . . . . . . . . . . . . . . . . . 109
installing the ignition pulse generator
installing the kickstarter
installing the kickstarter idler gear
installing the kickstarter shaft
installing the left engine case . . . . . . . . . . . . . . . . . . . 97
installing the locking lever . . . . . . . . . . . . . . . . . . . . . 99
Installing the oil pump gears
installing the oil pumps . . . . . . . . . . . . . . . . . . . . . . . 98
installing the outer clutch hub . . . . . . . . . . . . . . . . . 101
installing the piston
. . . . . . . . . . . . . . . . . . . . . . . . 105
installing the primary gear nut
installing the primary gear with the free-wheel-gear . . . . 98
. . . . . . . . . . . . . . . . 81
. . . . . . . . . . . . . . . . . . 90
. . . . . . . . . . . . . . . . . . 84
. . . . . . . . . . . . . . . . . . . . 91
. . . . . . . . . . . . . . . . . . . . . . 95
. . . . . . . . . . . . . . . . . . . . . . 89
. . . . . . . . . . . . . . . . . . . . . 77
. . . 84
. . . . . . . . . . . . . . . . . . . . . . 94
. . . . . . . . . . . 75
. . . . . . . . . . . . . . . . . . . . . . 85
. . . . . . . . . . . . . . . . . . . . . 76
. . . . . . . . . . . . . . . . . . 105
. . . . . . . . . . . . . . . . . . . . 102
. . . . . . . . . . . . . . . . . . . . . . 96
. . . . . . . . . . . . . . . . . . . 107
. . . . . . . . . . . . 104
. . . . . . . . . . . . . . . . . . . . . 103
. . . . . . . . . . . . . . 100
. . . . . . . . . . . . . . . . . 100
. . . . . . . . . . . . . . . . . . . 99
. . . . . . . . . . . . . . . . . 101
installing the rotor
. . . . . . . . . . . . . . . . . . . . . . . . . 105
installing the shift drum locating
installing the shift forks . . . . . . . . . . . . . . . . . . . . . . . 96
installing the shift lever . . . . . . . . . . . . . . . . . . . . . . 110
installing the shift rails . . . . . . . . . . . . . . . . . . . . . . . 97
installing the shift roller
installing the shift shaft . . . . . . . . . . . . . . . . . . . . . . . 99
installing the spark plug
installing the starter idler gear . . . . . . . . . . . . . . . . . 100
Installing the starter motor . . . . . . . . . . . . . . . . . . . . 111
installing the suction pump . . . . . . . . . . . . . . . . . . . 103
installing the timing chain . . . . . . . . . . . . . . . . . . . . 104
installing the timing chain guide rail . . . . . . . . . . . . . 105
installing the timing chain securing guide
installing the timing chain tensioning rail . . . . . . . . . . 104
installing the timing chain tensioner . . . . . . . . . . . . . 108
installing the transmission shaft . . . . . . . . . . . . . . . . . 96
installing the valve cover . . . . . . . . . . . . . . . . . . . . . 110
installing the water pump cover
mounting oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . 111
removing the engine from the universal mounting rack . 112
Engine disassembly
Draining the engine oil
draining the gear oil . . . . . . . . . . . . . . . . . . . . . . . . . 59
Preparations
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
removing the balance weight
removing the balancer shaft . . . . . . . . . . . . . . . . . . . . 67
removing the camshaft
removing the clutch cover
removing the clutch discs
removing the crankshaft
removing the cylinder head
removing the generator cover . . . . . . . . . . . . . . . . . . . 61
removing the ignition pulse generator
removing the kickstarter
removing the kickstarter idler gear
removing the left section of the engine case . . . . . . . . . 69
removing the locking lever . . . . . . . . . . . . . . . . . . . . . 68
Removing the oil filter . . . . . . . . . . . . . . . . . . . . . . . . 59
removing the oil pump gears
Removing the oil pump gears . . . . . . . . . . . . . . . . . 68-69
removing the outer clutch hub . . . . . . . . . . . . . . . . . . 66
removing the piston
. . . . . . . . . . . . . . . . . . . . . . . . . 62
removing the primary gear nut
removing the primary gear with the free-wheel-gear . . . . 69
removing the rotor
. . . . . . . . . . . . . . . . . . . . . . . . . . 63
removing the shift drum locating . . . . . . . . . . . . . . . . . 68
removing the shift forks . . . . . . . . . . . . . . . . . . . . . . . 71
removing the shift lever . . . . . . . . . . . . . . . . . . . . . . . 60
removing the shift rails . . . . . . . . . . . . . . . . . . . . . . . 70
removing the shift roller . . . . . . . . . . . . . . . . . . . . . . . 70
removing the shift shaft . . . . . . . . . . . . . . . . . . . . . . . 68
removing the spark plug
Removing the starter engine . . . . . . . . . . . . . . . . . . . . 60
removing the starter idler gear
removing the suction pump . . . . . . . . . . . . . . . . . . . . 64
removing the timing chain . . . . . . . . . . . . . . . . . . . . . 64
removing the timing chain guide rail . . . . . . . . . . . . . . 63
removing the timing chain securing guide
removing the timing chain tensioner . . . . . . . . . . . . . . 62
removing the timing chain tensioning rail . . . . . . . . . . . 64
. . . . . . . . . . . . . . . . 99
. . . . . . . . . . . . . . . . . . . . . . 97
. . . . . . . . . . . . . . . . . . . . . 110
. . . . . . . . . 104
. . . . . . . . . . . . . . . . 103
. . . . . . . . . . . . . . . . . . . . . . . 59
. . . . . . . . . . . . . . . . . . . 63
. . . . . . . . . . . . . . . . . . . . . . . 62
. . . . . . . . . . . . . . . . . . . . . 65
. . . . . . . . . . . . . . . . . . . . . 66
. . . . . . . . . . . . . . . . . . . . . . 71
. . . . . . . . . . . . . . . . . . . . 62
. . . . . . . . . . . . . 64
. . . . . . . . . . . . . . . . . . . . . . 65
. . . . . . . . . . . . . . . 67
. . . . . . . . . . . . . . . . . 68-69
. . . . . . . . . . . . . . . . . . 66
. . . . . . . . . . . . . . . . . . . . . . 60
. . . . . . . . . . . . . . . . . . 67
. . . . . . . . . . 64
186
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