The upper and lower crankcase halves are ma-
chined at the factory in the assembled state, so the
crankcase halves must be replaced as a set.
With a high-flash point solvent, clean off the mating sur-
faces of the crankcase halves and wipe dry.
Using compressed air, blow out the oil passages in the
Apply liquid gasket to the breather plate mating surface
[A] 1 ∼ 1.5 mm (0.04 ∼ 0.06 in.) thick, and then install the
Sealant - Three Bond: TB1207B
Apply a non-permanent locking agent to the threads and
tighten the bolts [A].
Torque - Breather Plate Bolts: 5.9 N·m (0.60 kgf·m, 52 in·lb)
Apply grease to the O-ring.
Install the oil jet nozzles [A].
Apply a non-permanent locking agent to the threads of oil
jet nozzle bolts.
Torque - Oil Jet Nozzle Bolts: 6.9 N·m (0.70 kgf·m, 61 in·lb)
Crankshaft and Connecting Rods
Camshaft Chain [A]
Transmission Shafts and Gears
Dowel Pins [B]
Shift Forks and Shift Rods
Before fitting the lower case on the upper case, check the
Be sure to hang the camshaft chain on the crankshaft.
Check to see that the shift drum and transmission gears
are in the neutral position.