Note the crankcase must be separated to service the crankshaft and conrod. |
Crankcase breather (pcv) cover
Remove the crankcase breather (pcv) cover (1).
Starter motor
Remove the starter motor (1).
Clutch
Remove the clutch component parts (1). Refer to “clutch removal” in section 5c .
Gearshift system
Remove the gearshift shaft (1) and gearshift cam plate (2). Refer to “gearshift shaft / gearshift cam plate removal and installation” in section 5b .
Starter torque limiter / starter clutch
Remove the starter torque limiter (1) and starter clutch (2) component parts. Refer to “starter torque limiter removal and installation” in section 1i and “starter clutch removal and installation” in section 1i .
Cam chain / cam chain tensioner / cam chain guide no. 1
Generator
Remove the generator cover (1) and rotor. Refer to “generator removal and installation” in section 1j .
Water pump
Gear position switch
Remove the gear position switch (1).
Oil pressure switch
Remove the oil pressure switch lead wire (1) and switch (2).
Oil filter
Remove the oil filter (1) with the special tool.
Special tool
(a): 09915–40610 (oil filter wrench)
Oil pan
Oil pressure regulator / oil strainer
Oil pump
Crankcase
Note loosen the crankcase bolts diagonally and smaller size ones first. |
Balancer shaft
Remove the balancer shaft assembly (1) and plug (2).
Transmission
Remove the transmission component. Refer to “transmission removal” in section 5b .
Crankshaft
Piston cooling oil jet
Remove the piston cooling oil jet (1) from the upper crankcase.
Piston / conrod
Caution be careful not to damage the cylinder wall by the conrod. |
Note scribe the cylinder number on the piston head. |
Crankshaft journal bearing
Remove the crankshaft journal bearings, upper and lower.
Caution
|
Note
|
Oil jet
Remove the oil jet (1) (for transmission) from the lower crankcase.
Oil gallery plug
Water jacket plug
Remove the water jacket plugs (1) from the upper crankcase.
Oil seal / bearing
Remove the oil seal and bearings if necessary. Refer to “transmission removal” in section 5b .
Breather oil return plate
Remove the breather oil return plate (1) from the upper crankcase.
Tire pressure and loading
Proper tire pressure and proper
tire loading are important factors.
Overloading your tires can lead to
tire failure and loss of vehicle control.
Check tire pressure each day
before you ride, and be sure the
pressure is correct for the vehicle
load according to the table below.
Tire pre ...
Headlight removal and installation
Removal
Remove the body cowling assembly. Refer to “exterior parts removal and
installation” in section 9d .
Remove the air intake pipes (1). Refer to “exterior parts removal and
installation” in section 9d .
Remove the wiring harness no. 2 (2) By
disconnecting the couplers and ...
Balancer shaft disassembly and assembly
Refer to “engine bottom side disassembly” (page 1d-
49).
Refer to “engine bottom side assembly” .
Disassembly
Remove the balancer shaft. Refer to “engine bottom side disassembly” .
Remove the washers, balancer gear and dampers
from the shaft.
Assembly
Assembly is in the re ...