Clutch — inspection Clutch drive plates Note: Wipe off engine oil from the clutch drive plates with a clean rag. Measure the thickness of drive plates with a vernier calipers. If each drive plate is not within the standard range, replace it with a new one. Drive plate...
Transmission — disassembly Caution: Be sure to identify each removed part as to its location, and lay the parts out in groups designated as "Drive" and "Driven", so that each will be restored to the original location during assembly. Countershaft Remove the О-ring (1), 2nd...
Transmission — reassembly Assemble the transfer in the reverse order of disassembly. Pay attention to the following points: Note: Always use new snap rings. Before installing the gears, coat lightly engine oil to the shafts and gears. Caution: Never reuse a snap ring. After...
Gearshift fork Gearshift fork to groove clearance Using a thickness gauge, check the gearshift fork clearance in the groove of its gear. The clearance for each gearshift fork plays an important role in the smoothness and positiveness of the shifting action. Shift...
Primary drive gear Primary drive gear inspection Visually inspect the gear teeth for wear and damage. If they are worn, replace the gear with a new one. Primary drive gear disassembly Disassemble the primary drive gear by removing the snap ring (1). 09900-06107: Snap...
Gearshift — disassembly and assembly Gearshift shaft/gearshift arm disassembly Remove the following parts from the gearshift shaft/gearshift arm (1). 2. Washer 3. Snap ring 4. Gearshift shaft return spring 5. Gearshift cam drive plate 6. Plate return spring ф Washer 7. Snap ring 8....
Crankcase of transmission Oil pump Remove the oil pump. Rotate the oil pump by hand and check that it moves smoothly. If it does not move smoothly, replace the oil pump assembly. Caution: Do not attempt to disassemble the oil pump assembly. The oil pump is available only as...
Crankcase-crankshaft bearing Crankcase-crankshaft bearing inspection Inspect the crankshaft journal bearings for any damage. If any, replace them with a specified set of bearings. Inspect the crankshaft journal for any damage. Measure the crankshaft journal O.D. with the...
Clutch cover Oil separater Remove the oil separator (1).
Gearshift cover Oil seal inspection Inspect the gearshift shaft oil seal for damage or wear on the lip. If any defects are found, replace the oil seal with a new one. Oil seal replacement Remove the gearshift shaft oil seal. Caution: The removed oil seal must be...
Engine reassembly — gearshift Install the gearshift cam stopper (2) its bolt (3), washer (4) and return spring (5). Note: Apply a small quantity of THREAD LOCK "1342" to the gearshift cam stopper bolt (3) and tighten it to the specified torque. 99000-32050: THREAD LOCK "1342"...
Engine reassembly — primary drive gear Install the thrust washer onto the crankshaft. Note: The grooved side (А) of the thrust washer faces the crankcase side. Install the key (1). Install the primary drive gear assembly (2) and the washer (3). Note: The convex side of the washer (3)...
Engine reassembly — cam drive idle gear/sprocket Insert a suitable bar to the holes of the primary drive gears and align the two gears. Install the cam drive idle gear/sprocket (2) Note: Align the punched marks (А) on the cam drive idle gear/sprocket and primary drive gear. Install the washer (3)...
Engine reassembly — clutch Install the thrust washer onto the countershaft. Note: The chamfer side (А) of thrust washer faces crankcase side. Install the needle bearing (1) and spacer (2) onto the countershaft. Apply engine oil to them. Install the primary driven gear...
Engine reassembly — clutch cover Install the gasket and dowel pins. Caution: Use the new gasket to prevent oil leakage. Install the clutch cover. Note: Set the impeller shaft end (А) to the cam drive idle shaft (В). Note: Fit the clamp to the bolt (С). Install the bracket (D). Fit...
Precautions in servicing* When handling the FI component parts or servicing the FI system, observe the following points for the safety of the system. Connector/coupler When connecting a connector, be sure to push it in until a click is felt. With a lock type coupler, be sure...