Clutch Cable — removal, inspection and assembly Removal 1. Remove the rider's seat (see page 16-13 ). 2. Disconnect the battery, negative lead first. 3. Slacken the cable locknut and release the adjuster at the clutch cover end to give maximum play in the cable. 4. Release the clutch cable from...
Disassembly Clutch Disassembly 1. Remove the rider's seat (see page 16-13 ). 2. Disconnect the battery, negative (black) lead first. 3. Release the clutch cable from the actuating arm (see page 4-5 ). 4. Remove the clutch cover. Discard the clutch cover gasket. 1....
Clutch Plate Inspection Friction Plate Thickness 1. If any friction plate thickness is outside the service limit, replace the friction plates as a set. 1. Clutch friction plate Friction plate thickness - all plates Standard: 3.00 mm Service limit: 2.80 mm Steel Plate...
Selector Shaft — removal and installation Removal 1. Note the position and orientation of the gear pedal crank in relation to the shaft, then remove the crank. 2. Remove the E-clip and washer from the gear pedal end of the gear change-shaft. 1. Gear change shaft; 2. E-clip; 3. Washer 3....
Selector Forks and Drum — removal, installation and inspection Removal 1. Remove the engine from the frame (see page 9-3 ). 2. Separate the two halves of the crankcase (see page 5-4 ). 3. Remove the output shaft from the crankcase (see page 7-10 ). 4. Remove the selector shaft (see page 7-6 ). 5. Remove and...
Input and Output Shafts Assemblies Removal Note: The input and output shafts may be removed from the upper crankcase after first separating the lower crankcase from the upper. Note: The rear needle roller bearing on the input shaft remains in the crankcase on removal of the shaft. 1....
Input Shaft — disassembly, inspection and assembly Disassembly Note: The numbers in brackets in the following text refer to the exploded view on page 7-14. Working from the opposite end to where the clutch assembly is fitted, dismantle the input shaft as follows: 1. Slide off the plain thrust washer...
Output Shaft — disassembly, inspection and assembly Note: The numbers in brackets in the following text refer to the exploded view on page 7-18 . Working from the opposite end to the drive sprocket, dismantle the output shaft as follows. Disassembly 1. Remove the output shaft bearing (1) and plain...
Starter Drive Gears/Sprag Clutch — removal, installation and inspection Removal Note: The sprag clutch may be detached after first removing the rider's seat and the battery (disconnect the negative (black) lead first). The alternator must also be removed. Refer to the relevant sections for removal procedures. 1. Remove...