Removing the clutch cover Order Job/Parts to remove Quantity Remarks Engine oil Drain. Refer to « Changing the engine oil ». 1 Clutch cable 1 2 Clutch cover 1 3 Clutch cover gasket 1 4 Dowel pin 2 5 Oil filler cap 1
Removing the pull lever shaft Order Job/Parts to remove Quantity Remarks 1 Circlip 2 2 Pull lever 1 3 Pull lever spring 1 4 Pull lever shaft 1 5 Oil seal 1 6 Bearing 2
Checking the clutch friction plates The following procedure applies to all of the friction plates. 1. Check: Friction plate Damage/wear → Replace the friction plates as a set. 2. Measure: Friction plate thickness Out of specification → Replace the friction plates as a set. Note:...
Checking the clutch plates The following procedure applies to all of the clutch plates. 1. Check: Clutch plate Damage → Replace the clutch plates as a set. 2. Measure: Clutch plate warpage (with a surface plate and thickness gauge «1») Out of specification → Replace the...
Checking the clutch springs The following procedure applies to all of the clutch springs. 1. Check: Clutch spring Damage → Replace the clutch springs as a set. 2. Measure: Clutch spring free length «a» Out of specification → Replace the clutch springs as a set. Clutch spring...
Checking the clutch housing 1. Check: Clutch housing dogs Damage/pitting/wear → Deburr the clutch housing dogs or replace the clutch housing. Note: Pitting on the clutch housing dogs will cause erratic clutch operation. 2. Check: Bearing Damage/wear → Replace the bearing and...
Checking the clutch boss 1. Check: Clutch boss splines. Damage/pitting/wear → Replace the clutch boss. Note: Pitting on the clutch boss splines will cause erratic clutch operation.
Checking clutch pull lever shaft and pull rod 1. Check: Pull lever shaft pinion gear teeth «1» Pull rod teeth «2» Damage/wear → Replace the pull rod and pull lever shaft pinion gear as a set. 2. Check: Pull rod bearing. Damage/wear → Replace.
Installing the clutch 1. Install: Clutch damper spring seat «1» Clutch damper spring «2» 2. Install: Friction plate 3 «1» Clutch plate 2 «2» Note: Lubricate the engine oil. 3. Install: Wire circlip «1» 4. Install: Clutch housing «1» Note: Align the projection of clutch...
Removing the shift shaft and stopper lever Order Job/Parts to remove Quantity Remarks Clutch assembly Refer to « Clutch ». Shift arm and shift rod Refer to « Engine removal ». 1 Circlip 1 2 Washer 1 3 Shift shaft 1 4 Collar 1 5 Shift shaft spring 1 6 Washer 1 7 Stopper screw 1 8 Stopper...
Removing the transmission 1. Remove: Drive axle assembly «1» Shift drum retainers «2» Shift fork guide bars Shift fork «L» and «R» Shift drum assembly Shift fork «C» 2. Remove: Bearing housing «1» Main axle assembly «2» a. Insert two bolts «3» of the proper size, as shown in...
Checking the shift forks The following procedure applies to all of the shift forks. 1. Check: Shift fork cam follower «1» Shift fork pawl «2» Bends/damage/scoring/wear → Replace the shift fork. 2. Check: Shift fork guide bar Roll the shift fork guide bar on a flat surface....
Checking the shift drum assembly 1. Check: Shift drum grooves «1». Damage/scratches/wear → Replace the shift drum assembly. Shift drum segment «2». Damage/wear → Replace the shift drum assembly. Shift drum bearing «3». Damage/pitting → Replace the shift drum assembly.
Checking the transmission 1. Measure: Main axle runout (with a centering device and dial gauge «1») Out of specification → Replace the main axle. Main axle runout limit: 0.08 mm (0.0032 in) 2. Measure: Drive axle runout (with a centering device and dial gauge «1») Out of...
Installing the transmission 1. Install: Bearing «1» Oil pipe «2» Note: Make the seal side of bearing face to the outside and install it close to the right end face of the crankcase. 2. Install: Main axle assembly «1» Bearing housing «2» Shift fork «C» Shift drum assembly Shift...
Removing the drive chain Order Job/Parts to remove Quantity Remarks Drive sprocket Refer to « Engine removal ». 1 Drive chain guard 1 2 Drive chain 1 1. Stand the vehicle on a level surface. Warning! Securely support the vehicle so that there is no danger of it falling...
Checking the drive chain 1. Measure: Measure the dimension between 15-links on the inner side «a» and outer side «b» of the roller and calculate the dimension between pin centers. Dimension «c» between pin centers = (Inner dimension «a» + Outer dimension «b»)/2 15-link...
Checking the drive sprocket 1. Check: Drive sprocket More than 1/4 tooth «a» wear → Replace the drive chain sprockets as a set. Bent teeth → Replace the drive chain sprockets as a set. b. Correct; 1. Drive chain roller; 2. Drive chain sprocket