Removing engine components without removing the engine from the motorcycle The parts listed below can be removed/installed without removing the engine from the motorcycle. The table contains page numbers describing the removal/installation procedure. Left side of the engine DETAILS REMOVAL INSTALLATION Leading Star 3-4 -...
Removing the engine Clean the engine before removing it from the motorcycle. Before removing the engine from the motorcycle, do the following: Remove the side plastic on the left and right ( section 5-3 ). Remove the saddle ( section 5-3 ). Remove the gas tank (...
Engine Installation Install the engine in the reverse order of removal. Install the brackets, bolts and nuts as shown below. Note. The motor nuts are self-locking and are not intended for subsequent installation. Use new nuts. Tighten the nuts to the specified torque....
Engine disassembly Remove the oil line (1). Remove the cylinder head cover (2) and gasket (3). Remove the chain tensioner plug. Note. Turn the chain tensioner pusher screw clockwise until it stops. Remove the tensioner (4) chains. Remove the bracket (5) clutch cable...
Camshaft/Cylinder Head Inspection and Maintenance Attention! Determine the position of each part being removed. Organize parts by accessory (for example, inlet or outlet) so that they can be assembled in their original position. Camshaft Both shafts should be checked for journal runout and also for...
Cylinder inspection and maintenance Cylinder deformation Check the cylinder mating surface for flatness using a straight edge and feeler gauge. Check the gap in several places. If the gap exceeds the tolerance, replace the cylinder with a new one. 09900-20803: Dipstick Non-flatness of...
Checking and servicing the piston and rings Piston diameter Measure the piston diameter with a micrometer 15 mm from the edge of the skirt. If the piston diameter is less than permissible, replace the piston with a new one. 09900-20204: Micrometer (75–100 mm) Piston diameter. Allowable limit:...
Checking and servicing the connecting rod Connecting rod upper bore inner diameter Measure the inner diameter of the hole in the upper head of the connecting rod with an indicator bore gauge. If the diameter exceeds the permissible limit, replace the connecting rod with a new one....
Runout of crankshaft journals Place the crankshaft on the prisms and measure the runout of the journals with a dial indicator. If the runout exceeds the permissible value, replace the crankshaft with a new one. 09900-20607: Indicator (1/100 mm) 09900-20701: Magnetic stand...
Inspection of the balancer shaft 1. Washer; 2. Washer; 3. Pin; 4. Spring (4 things); 5. Inner ring; 6. Driven gear; 7. Washer; 8. Key
Pan oil filter Examination Check the filter for damage and dirt. Cleaning Blow out the pan filter with compressed air.
Engine assembly Reassemble the engine in the reverse order of disassembly. Subsequent operations require special attention or special precautions. Note. Before assembly, lubricate all rotating and sliding parts with engine oil. Crankcase bearings Install the...
Oil radiator Checking the radiator oil lines Check the oil lines for damage and oil leaks. If any defects are found, replace the oil lines with new ones. Checking and cleaning the oil cooler Remove contaminants from the radiator by blowing with compressed air....