Clutch cable — removal Warning! Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. Perform the...
Clutch cable — inspection 1. Check the inner cable for free movement through the outer cable. 2. Examine the inner cable for frayed strands. 3. Examine the two inner cable nipples for signs of looseness and damage. Replace the cable if necessary.
Clutch cable — installation Warning! Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. 1. Position...
Clutch — removal Warning! Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. Perform the...
Friction plate inspection Thickness Note: If any friction plate thickness is outside the service limit, replace the friction plates as a set. 1. Measure the thickness of the friction plate. 1. Clutch friction plate 2. For the clutch friction plate thickness, refer to Clutch...
Steel plate inspection Bend/warp Check all plates for bend and warp as follows: 1. Place the plate being checked on a clean surface plate and attempt to pass a feeler gauge of the maximum service limit thickness between the steel plate and surface plate. If the feeler...
Clutch pack height The clutch pack height should only be measured if the friction plates and the steel plates have been replaced. The clutch pack height is critical for a smooth operation of the gear change and needs to be measured prior to installation. If used steel...
Clutch — installation 1. To fully engage the outer drum, insert a suitable tool to preload and align the primary gear and backlash eliminator gear through the hole shown in the illustration below. 1. Alignment hole; 2. Outer drum 2. Position the clutch outer drum...
Transmission — exploded view Exploded view – input and output shafts Exploded view – gear selectors and drum Exploded view – gear change lever
Gear change linkage — removal Warning! Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. Perform the...
Gear change linkage — installation 1. Locate the gear change linkage through the frame as noted for removal. 2. Attach the front ball joint to the transmission linkage. 3. Attach the rear ball joint to the foot control. 4. Refit the wire clips to retain the ball joints. Ensure the...
Gear change shaft — removal Warning! Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. Perform the...
Gear change shaft — installation 1. Rotate the selector drum to the neutral position. 1. Detent wheel; 2. Neutral position 2. Using grease to NLGI 2 specification, lubricate the lip of the seal for the gear change shaft. 1. Gear change shaft seal; 2. Gear change shaft bearing...
Selector forks and drum — removal Warning! Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. Perform the...
Selector forks and drum — inspection Inspect all bearings for damage or wear. Renew as necessary. Inspect the selector forks and selector grooves for wear beyond the service limits. Renew the components as necessary. Refer to the specifications table ( see Transmission ). 1. Examine...
Selector forks and drum — installation 1. Position the input shaft selector fork into the crankcase, locating the fork into the selector groove on the input shaft. Ensure the fork is fitted in the position noted during removal. 1. Input shaft selector fork; 2. Input shaft 2. Using clean...
Input and output shaft assemblies — removal Warning! Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. Note: The...
Input and output shaft assemblies — installation 1. If removed, check the transmission oil tube for blockages and contamination. Carefully fit new O-rings to the transmission oil tube and insert the tube into the crankcase, ensuring the tag on the tube locates in the slot in the crankcase. 2....
Input shaft — disassembly Note: The numbers in brackets in the following text refer to the exploded view on Exploded view - input shaft . Working from the opposite end to where the clutch assembly is fitted, dismantle the input shaft as follows: 1. Slide off the plain thrust...
Input shaft — inspection 1. Examine all gears, bearings and bushes and thrust washers for damage, distortion, chipped teeth and wear beyond the service limits. Replace all defective components and always use new circlips to assemble the shaft. 2. Thoroughly clean the...
Input shaft — assembly Note: The numbers in brackets in the following text refer to the exploded view on Exploded View - Input Shaft . Lubricate each gear, thrust washer and bush with clean engine oil during assembly. Warning! When using a press, always wear overalls,...
Output shaft — disassembly Note: The numbers in brackets in the following text refer to the exploded view on Exploded view - output shaft . Working from the opposite end to the drive sprocket, dismantle the output shaft as follows. 1. Remove the output shaft bearing (1) and...
Output shaft — inspection 1. Examine all gears, bearings, bushes and thrust washers for damage, distortion, chipped teeth and wear beyond the service limits. Replace all suspect components and always use a new circlip to assemble the shaft.
Output shaft — assembly Note: The numbers in brackets in the following text refer to the exploded view on Exploded view - output shaft . Lubricate each gear and bush with clean engine oil during assembly. Examine all gears, bearings and sleeves for damage, chipped teeth...
Final drive chain For safety and to prevent excessive wear, the drive chain must be checked, adjusted and lubricated in accordance with scheduled maintenance requirements. Checking, adjustment and lubrication must be carried out more frequently for extreme conditions...
Final drive chain lubrication Lubrication is necessary every 200 miles (300 km) and also after riding in wet weather, on wet roads, or any time that the chain appears dry. Use the special drive chain lubricant as recommended in the specification section. Correct application is...
Final drive chain free-movement inspection 1. Maximum movement position Warning! Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to...
Final drive chain free-movement adjustment Warning! Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. The vertical...
Final drive chain and sprocket wear inspection Warning! Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. 1. Measure...
Drive chain replacement Rivet link type As the drive chain passes through the swinging arm casting, the chain must be split for removal from the motorcycle. Removal of the swinging arm is not required for drive chain replacement. The following instructions for the...
Front sprocket — removal Warning! Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. Position the...
Front sprocket — installation Warning! Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. 1. Fit the...
Final drive — removal Warning! Make sure the motorcycle is stabilised and adequately supported. A correctly supported motorcycle will help prevent it from falling. An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle. Perform the...
Rear sprocket carrier bearings — disassembly Perform the following operations: Final drive - removal 1. Remove and discard the seal. 1. Sprocket carrier; 2. Seal 2. Remove and discard the bearing circlip. 1. Sprocket carrier; 2. Circlip Warning! Always wear eye, hand and face protection when...
Rear sprocket carrier bearings — assembly Warning! When using a press, always wear overalls, eye, face and hand protection. Objects such as bearings frequently break-up under load and the debris caused during break-up may cause damage and injury to unprotected parts of the body. Never wear...
Rear sprocket — removal Caution! Do not allow the wheel to rest on the brake disc, as this may damage the disc. Support the wheel on wooden blocks, equally spaced around the rim, such that the brake disc is raised above the ground. Perform the following operations: Rear...
Rear sprocket — installation Caution! Do not allow the wheel to rest on the brake disc, as this may damage the disc. Support the wheel on wooden blocks, equally spaced around the rim, such that the brake disc is raised above the ground. 1. If necessary, replace any rear...