DISASSEMBLY -- ENGINE REMOVED
1. The knock pins (2), timing chain guide, and rubber
plug must be in place.
A. Knock Pin
B. Timing Chain Guide and Rubber Plug
C. Timing Chain
D. Camshaft Chain
bearing cap must be installed in
half lightly with two bolts.
camshaft chain must be engaged
The primary chain must be engaged with the crank-
shaft and the secondary shaft synchronized (Pg. 109).
set rings for bearing outer races (3)
the upper crankcase
6. Outer race
drive shaft needle bearing must be fit
with a set pin correctly and must be contact with the
7. Check that there are no clearance between the sec-
driven sprocket and the
ball bearing inner race and the
the area of the mating surface
of the lower
half, as shown below.
~f I.iquid gasket a~here~ to any areas not
the engme Oil passages may be
obstructed, causing engine seizure and possible accident
Liquid Gasket Applied Area
eFit the lower crankcase half on the upper one, putting
the fingers of each shift fork into the grooves of the
~ =a~a~~rlin~:!;h::n~etge~f P~~:h~t:~
tween crankcase halves.
ePut each ofthe bolts (37) into the lower crankcase half
(See Fig. F17), and finger-tighten them.
eFoliow the tightening sequence numbers on the lower
cran kcase half: tighten the 8 mm bolts (18) first to
about 1.5 kg-m (11 ft-Ibs) and finally to 2.5 kg-m (18.0
ft-Ibs) of torque.
eTighten the 6 mm bolts (19) to 1.0 kg-m (87 in-Ibs)
eCheck to see that
drive shaft, driven shaft, and
output shaft turn freely
Spinning the driven shaft,
transmission through all gears to make certain
there is no binding and that all gears shift properly.
eApply a non-permanent locking agent to the threads
of output shaft bearing cap bolts (4), and tighten them
to 1.2 kg-m (104 in-Ibs) of torque.
Apply a non-permanent locking agent to the threads.
-Clean the screen and push it in the screen body.
elnstall the screen body with screws
-Check that nozzles (2)
in place on the mating
face of low crankcase half and oil pan (See Figs. E167
and E168), and then install the oil
elnstall the oil pump
eTurn the engine
ePut each of the 6 mm bolts (10) into the upper crank-
case half as shown
F17, and tighten them to 1.0
kg-m (87 in-Ibs) of torque.
NOTE: Do not forget
install the pick-up coil lead
guide with the front right 6 mm bolt with 85 mm length.
starter motor (Pg. 81).
elnstall the alternator cover (Pg. 85), clutch cover, left
cover, and external shift mechanism cover (Pg.
elnstall the engine (Pg. 98)
NOTE: When the drive shaft is to be disassembled,
remove the clutch while the engine is in the frame (Pg.
When the driven shaft is to be disassembled,