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.
Wiring harness routing diagram
Wiring harness no. 2
Tapping clamp
: insert the clamp from the front side. Place the turn signal
and position light couplers in front of the clamp.
Steel clamp
: clamp the wiring harness at the blue taping point. Bend
the steel clamps to the front side.
...
Gearshift shaft construction
Gearshift shaft
Washer
Snap ring
Gearshift shaft return spring
Gearshift cam drive plate
Gearshift plate return spring
8.5 N·m (0.85 Kgf-m,
6.0 Lbf-ft)
13 N·m
(1.3 Kgf-m, 9.5 Lbf-ft)
19 N·m
(1.9 Kgf-m, 13.5 Lbf-ft)
Apply ...
Rear suspension components
Rear shock absorber
Rear shock absorber mounting nut
Cushion rod
Cushion rod mounting nut
Cushion lever
Cushion lever mounting nut
Swingarm pivot lock-nut
Swingarm pivot shaft
Swingarm pivot nut
Swingarm
Chain case
Plate
Chain adjus ...