Refer to “engine top side disassembly” .
Refer to “engine top side assembly” .
Camshaft identification
The exhaust camshaft has the embossed letters “ex” and the intake camshaft has the embossed letters “in”.
Cam wear
Check the camshaft for wear or damage.
Measure the cam height “a” with a micrometer.
Replace a camshaft if the cams are worn to the service limit.
Special tool
: 09900–20202 (micrometer (25 – 50
mm))
Cam height “a” service limit (in.): 37.38 Mm (1.472 In) service limit (ex.): 36.58 Mm (1.440 In)
Camshaft runout
Measure the runout using the dial gauge. Replace the camshaft if the runout exceeds the limit.
Special tool
(a): 09900–20607 (dial gauge)
(b): 09900–20701 (dial gauge chuck)
(c): 09900–21304 (v blocks)
Camshaft runout (in. & Ex.) Service limit: 0.10 Mm (0.004 In)
Camshaft journal wear
Inspect the camshaft journal wear in the following procedures:
Special tool
(a):
09900–22301 (plastigage (0.025 – 0.076
Mm))
(b):
09900–22302 (plastigage (0.051 – 0.152
Mm))
Refer to “engine top side assembly” .
Note do not rotate the camshafts with the plastigauge in place. |
Tightening torque camshaft journal holder bolt: 10 n·m (1.0 Kgfm, 7.0 Lbf-ft)
Camshaft journal oil clearance (in. & Ex.) Service limit: 0.150 Mm (0.0059 In)
Special tool
(c): 09900–20602 (dial gauge)
(d): 09900–22403 (small bore gauge
(18 –
35 mm))
(e): 09900–20205 (micrometer (0 – 25
mm))
Camshaft journal holder i.D. (In. & Ex.) Standard: 24.012 – 24.025 Mm (0.9454 – 0.9459 In)
Camshaft journal o.D. (In. & Ex.) Standard: 23.959 – 23.980 Mm (0.9433 – 0.9441 In)
Diagnostic information and procedures
Engine mechanical symptom diagnosis
Refer to “engine symptom diagnosis” in section 1a .
Compression pressure check
The compression pressure reading of a cylinder is a
good indicator of its internal condition.
The decision to overhaul the cylinder is often based on
the results of a compressio ...
Rear suspension inspection
Inspect rear suspension
every 12 000 km (7 500 miles, 24 months)
Inspect the rear shock absorber for oil leakage and
check that there is no play in the swingarm.
Replace any defective parts, if necessary. Refer to “rear shock absorber removal
and installation” in section 2c , “cushion lever ...
Ignition switch inspection
Inspect the ignition switch in the following procedures:
remove the air cleaner box. Refer to “air cleaner box removal and
installation” in section 1d .
Disconnect the ignition switch lead wire coupler (1).
Inspect the ignition switch for continuity with a tester.
If ...