Service manual

CRANKCASE ..............................................................................................4-56
STARTER MOTOR, TIMING CHAIN AND OIL FILTER ......................4-56
CRANKCASE ......................................................................................4-58
CRANKCASE BEARING .....................................................................4-59
REMOVING THE OIL PUMP DRIVE GEAR .......................................4-60
SEPARATING THE CRANKCASE ......................................................4-60
CHECKING THE TIMING CHAIN AND GUIDE ...................................4-61
CHECKING THE OIL STRAINER AND OIL DELIVERY PIPE ............4-61
CHECKING THE CRANKCASE ..........................................................4-62
CHECKING THE BEARINGS ..............................................................4-62
ASSEMBLING THE CRANKCASE ......................................................4-62
INSTALLING THE SHIFT LEVER .......................................................4-63
INSTALLING THE OIL PUMP DRIVE GEAR ......................................4-64
CRANKSHAFT AND OIL PUMP ................................................................4-65
OIL PUMP ...........................................................................................4-66
REMOVING THE CRANKSHAFT .......................................................4-67
CHECKING THE OIL PUMP ...............................................................4-67
CHECKING THE CRANKSHAFT ........................................................4-68
INSTALLING THE CRANKSHAFT AND BALANCER .........................4-69
TRANSMISSION .........................................................................................4-70
CHECKING THE SHIFT FORK ...........................................................4-72
CHECKING THE SHIFT CAM .............................................................4-72
CHECKING THE TRANSMISSION .....................................................4-73
CHECKING THE SECONDARY SHAFT
AND DRIVEN SPROCKET ..............................................................4-73
CHECKING THE CHAIN .....................................................................4-74
CHECKING THE STOPPER LEVER AND STOPPER WHEEL ..........4-74
INSTALLING THE TRANSMISSION ...................................................4-74
MIDDLE GEAR ...........................................................................................4-76
MIDDLE DRIVE SHAFT ......................................................................4-76
MIDDLE DRIVEN SHAFT ....................................................................4-77
REMOVING THE MIDDLE DRIVE SHAFT .........................................4-79
REMOVING THE MIDDLE DRIVEN SHAFT .......................................4-79
CHECKING THE PINION GEAR .........................................................4-81
SELECTING THE MIDDLE DRIVE AND DRIVEN GEAR SHIM .........4-82
INSTALLING THE MIDDLE DRIVEN SHAFT .....................................4-85
INSTALLING THE MIDDLE DRIVE SHAFT ........................................4-87
MEASURING THE MIDDLE GEAR BACKLASH .................................4-87
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