2. Lower crankcase
a. Install the shift cam and secure it with the guide pin. Install the stopper plate and bolt and tighten securely.
b. Install the neutral switch.
c. Install the transmission drive axle assembly into the crankcase.
INSPECTION AND REPAIR
A. Cylinder Head Cover
Place head cover on a surface plate. There should be no warpage. Correct by re-surfacing as follows:
Place #400 or #600 grit wet sandpaper on surface plate and re-surface head cover using a figure-eight sanding pattern. Rotate head cover several times to avoid removing too much material from one side.
B. Cylinder Head
ELECTRICAL COMPONENTS
Proper periodic maintenance is important. Especially important are the maintenance services
related to emissions control. These controls not only function to ensure cleaner air but
are also vital to proper engine operation and maximum performance. In the following tables
of periodic maintenance, the services related to emissions control are grouped separately.
PERIODIC MAINTENANCE EMISSION CONTROL SYSTEM
ENGINE REMOVAL
NOTE:
It is not necessary to remove the engine in order to remove the cylinder head, cylinder, or pistons.
A . Preparation for Removal
J. Crankcase Disassembly
1. Remove the upper crankcase bolts, starting the highest numbered bolt. Turn over the engine and remove the lower crankcase bolts,
CRANKCASE TORQUE SEQUENCE
UPPER CASE
LOWERCASE
P. Middle Gear
1. Damper disassembly
NOTE:
Disassembly of the middle gear damper requires the damper compressor (special tool) and a hydraulic press.
a. Place the middle drive shaft in a press with the damper compressor (special tool) in place as shown.
SWING ARM
A. Inspection
1. Free play inspection
Remove the rear wheel and both shock absorbers. Grasp the swing arm and try to move it from side to side as shown. There should be no noticeable side play.
H. Oil Pump Removal and Disassembly
1. Remove the strainer cover. Note the wire harness clip position.
2. Remove the oil pump securing bolts and remove the sprocket cover and oil pump assembly.
CONSUMER INFORMATION
Note:
The information presented represents results obtainable by skilled drivers under controlled road and vehicle conditions, and the information may not be correct under other conditions.
