Refer to “engine bottom side disassembly” (page 1d- 49).
Refer to “engine bottom side assembly” .
Conrod small end I.D.
Measure the conrod small end inside diameter using the small bore gauge.
If the conrod small end inside diameter exceeds the service limit, replace the conrod.
Special tool
(a): 09900–20602 (dial gauge)
(b): 09900–22401 (small bore gauge
(10 – 18
mm))
Conrod small end i.D.
Service limit: 15.040 Mm (0.5921 In)

Conrod big end side clearance
Special tool
(a): 09900–20803 (thickness gauge)
Conrod big end side clearance service limit: 0.30 Mm (0.012 In)

Special tool
(b): 09900–20205 (micrometer (0 –
25 mm))
(c): 09900–20605 (dial calipers (10
– 34
mm))
Conrod big end width standard: 19.95 – 20.00 Mm (0.7854 – 0.7874 In)
Crank pin width standard: 20.10 – 20.15 Mm (0.7913 – 0.7933 In)

Crankshaft runout
Support the crankshaft using v-blocks as shown, with the two end journals resting on the blocks. Set up the dial gauge as shown, and rotate the crankshaft slowly to read the runout. Replace the crankshaft if the runout exceeds the service limit.
Special tool
(a): 09900–20607 (dial gauge)
(b): 09900–20701 (dial gauge chuck)
(c): 09900–21304 (v blocks)
Crankshaft runout service limit: 0.05 Mm (0.002 In)

Conrod crank pin bearing removal and
installation
Conrod crank pin bearing inspection and
selectionClutch installation
Install the primary driven gear assembly (1).
Caution
if it is difficult to install the primary driven
gear, rotate the crankshaft.
Be sure to engage the oil pump drive
sprocket with the primary driven gear.
Install the spacer (2) and bea ...
Starter relay removal and installation
Removal
Turn the ignition switch off.
Remove the front seat. Refer to “exterior parts
removal and installation” in section 9d (page 9d-
6).
Disconnect the battery (–) lead wire (1) from the
battery.
Remove the starter relay cover (2) and disconnect
the starter rel ...
Fuel tank cap
To open the fuel tank cap, insert
the ignition key into the lock and
turn it clockwise. With the key
inserted, lift up with the key and
open the fuel tank cap. To close
the fuel tank cap, push the cap
down firmly with the key in the cap
lock.
Fuel level
Fi ller neck
Wa ...