Oil filter
- Remove the oil filter with the special tool.
09915-40610: Oil filter wrench
- Remove the generator cover.
- Remove the starter torque limiter (1) and starter idle gear (2).
- Remove the bushings (1) from the crankcase and generator cover.
Clutch cover
- Remove the water pump case.
Water pump disassembly (5-13).
Clutch
- Remove the clutch cover.
- Hold the generator rotor with the special tool.
09930-44541: Rotor holder
- While holding the generator rotor, remove the clutch spring set bolts and springs diagonally.
- Remove the pressure plate (1).
- Remove the clutch push piece, bearing and thrust washer.
- Remove the clutch push rod (1).
- Remove the clutch drive and driven plates.
- Remove the wave washer (2) and wave washer seat (3).
- Unlock the clutch sleeve hub nut.
- While holding the clutch sleeve hub with the special tool, remove the clutch sleeve hub nut.
09920-53740: Clutch sleeve hub holder
- Remove the washer (1) and (2).
- Remove the clutch sleeve hub (3).
- Remove the thrust washer (4).
- Remove the primary driven gear assembly.
- Remove the needle roller bearing, spacer and thrust washer.
Gear position switch
- Remove the gear position switch.
- Remove the gear position switch contacts (1) and springs (2).
Oil sump filter
- Remove the oil sump filter.
Oil pump
- Remove the oil pump driven gear (1) by removing the snap ring.
09900-06107: Snap ring pliers
- Remove the pin (2) and washer (3).
Note: Do not drop the snap ring, pin and washer into the crankcase.
- Hold the generator rotor with the special tool.
09930-44541: Rotor holder
Cam drive idle gear/sprocket
- While holding the generator rotor, remove the cam drive idle gear/sprocket nut.
- Insert a suitable bar into the holes of primary drive gears to align the teeth of scissors gears.
- Remove the cam drive idle gear/sprocket and cam chain.
- Remove the key (1).
Primary drive gear
- Hold the generator rotor with the special tool.
09930-44541: Rotor holder
- While holding the generator rotor, remove the primary drive gear nut.
Caution: This bolt has left-hand thread. Turning it counterclockwise may cause damage.
- Remove the washer (1).
- Remove the primary drive gear assembly (2).
- Remove the key (1) and thrust washer (2).
Genenrator rotor
- While holding the generator rotor with the special tool, remove its bolt.
09930-44541: Rotor holder
- Install the special tool to the boss.
- Remove the generator rotor by turning the special tool while holding the generator rotor with the special tool.
09930-30450: Generator rotor remover bolt
- Remove the key (1) and starter driven gear (2).
Gearshift
- Remove the gearshift cover.
- Draw out the gearshift shaft (1).
- Remove the gearshift cam plate (2).
- Remove the gearshift cam stopper (3).
- Remove the engine sprocket spacer (4).
- Remove the cam drive idle gear shaft (5).
- Remove the crankcase bolts.
- Separator the crankcase into 2 parts, right and left with the crankcase separating tool.
09920-13120: Crankcase separating tool
Note:
- Fit the crankcase separating tool, so that the tool arms are in parallel with the side of crankcase.
- The crankshaft and transmission components should remain in the left crankcase half.
- When separating the crankcase, tap the end of the countershaft with a plastic hammer.
- Remove the gearshift fork shafts, gearshift forks and gearshift cam.
- Remove the countershaft and driveshaft.
- Remove the crankshaft.