INTRODUCTION TO DISASSEMBLY
Detail has not been spared in this section in order that the motorcycle cannot only be taken apart
but also put back together properly as well. Photographs, diagrams, notes, cautions, warnings, and
detailed descriptions have been included wherever necessary. Nevertheless, even a detailed account
has limitations; a certain amount of basic knowledge is also required for successful work.
Especially note the following:
Watch for sharp
especially during major engine disassembly and assembly. Protect your
hands with gloves or a piece of thick cloth when lifting the engine or turning it over.
Before removal and disassembly, clean the motorcycle. Any dirt entering the engine, carburetor
or other parts will work as an abrasive and shorten the life of the motorcycle. For the same
reason, before installing a new part, clean off any dust or metal fillings.
(3) Tightening Sequence
Where there is a tightening sequence indication in this Service Manual; the bolts, nuts, or screws
must be tightened in the order and method indicated. When installing a part with several bolts,
nuts, or screws; they should all be started in their holes and tightened to a snug fit. Then tighten
according to the tightening sequence, to the specified torque.
This is to avoid
distortion of the part and/or causing gas or oil leakage. Conversely when loosening the bolts,
nuts, or screws; loosen all of them about a quarter of turn and then remove them.
The torque values given in this Service Manual should always be adhered to. Either too little or
too much torque may lead to serious damage. Use a good quality, reliable torque wrench.
Common sense should dictate how much force is necessary in assembly and disassembly. If a
part seems especially difficult to remove or install, stop and examine what may be causing
the problem. Whenever tapping is necessary, tap lightly using a wooden or plastic-faced mallet.
Use an impact driver for screws (particularly for the removal of screws held by a locking agent)
in order to avoid damaging the screw heads.
Don't use just any oil or grease. Some oils and greases in particular should be used only in certain
applications and may be harmful if used in an application for which they are not intended.
(7) Battery Ground
Before performing any disassembly operations on the motorcycle, remove the ground (-) lead
from the battery to prevent the possibility of accidentally turning the engine over while partially
(8) Engine Rotation
When turning the crankshaft by hand, always turn it in the direction of normal rotation; which is
counterclockwise, viewed from the left side of the engine. This will ensure proper adjustments.
Engine wear is generally at its maximum while the engine is warming up and before all the rubbing
surfaces have an adequate lubricative fi lm.
During assembly, oil or grease (whichever is more
suitable) should be applied to any rubbing surface which has lost its lubricative film. Old grease
and dirty oil should be cleaned off. Deteriorated grease has lost its lubricative quality and may
contain abrasive foreign particles.
A part installed using a press or driver, such as a wheel bearing, should first be coated with oil
on its outer or inner circumference so that it will go into place smoothly.
(11) Oil Seal, Grease Seal
Replace any oil or grease seals that have been removed with new ones, as removal generally
damages the .seals. A seal guide is required for certain oil and grease seals du ring installation to
avoid damage to the seal lips. Before a shaft passes through a seal, apply a little oil, preferably
high temperature grease on the lips to reduce rubber to metal friction.
(12) Gasket, 0 Ring
When in doubt as to the condition of a gasket or O ring, replace it with a new one. The mating
surfaces around the gasket should be free of foreign matter and perfectly smooth to avoid oil or