OIL PUMP AND OIL PAN
1 Chain cover
2 Oil pump sprocket
3 Oil pump drive sprocket
4 Oil pump cover
5 Inner rotor
6 Spring
7 Relief valve
8 Shaft
9 Dowel pin
10 Outer rotor
11 Dowel pin
12 O-ring
UPPER CRANKCASE
LOWER CRANKCASE
TRANSMISSION
1. Inspect:
• Shift fork cam follower 1
• Shift fork pawl 2
• Guide bar 3
Scoring/Bends/Wear-> Replace.
CLUTCH
1. Inspect:
• Clutch housing dogs 1
Cracks/Pitting (edges): Moderate -> Deburr.
Severe -> Replace clutch housing.
2. Inspect
• Clutch housing bearing 2
• Spacer 3
OIL PUMP
1. Remove:
•Screw
• Pump cover 1
• Pump shaft 2
• Pin 3
• Inner rotor 4
• Outer rotor 5
• Spring 6
• Relief valve 7
CRANKSHAFT AND CONNECTING ROD
Crankshaft Runout
1. Place both ends of crankshaft on V-blocks.
2. Rotate Crankshaft
3. Measure the crankshaft runout at main journal bearings. Use a Dial Gauge (90890-03097).
CYLINDER
1. Inspect the cylinder walls for vertical scratches and Rebore or Replace cylinder as required.
2. Measure the cylinder inside diameter.
1. Measure the valve stem clearance
Use a bore gauge 3 to determine the valve guide inside diameter.
Valve Guide Inside Diameter Limit: 5.05 mm (0.199 in)
