Crankcase

Crankcase disassembly

1.    Remove the right-front crankcase cover.

2.    Remove the upper crankcase bolts, starting the highest numbered bolt.

Turn over the engine and remove the lower crankcase bolts.

CRANKCASE TIGHTENING SEQUENCE

LOWERCASE

UPPERCASE

*6 mm

3. Separate the lower case from the engine. Use a soft rubber hammer to carefully separate the crankcase.

I. Upper crankcase

1. Remove the transmission assembly.

2. Remove the A.C.G. shaft cover.

3. Remove the oil spray nozzle.

4. Carefully remove the A.C.G. shaft from the gear.

5. Remove the gear from the chain.

6. Straighten the lock washer tab and remove the bolt securing the starter idle gear shaft. Remove the shaft and starter idle gear.

J. Lower crankcase

1.    Remove the dowel pin and "O-ring".

2.    Remove the shift bar stopper securing screw and bolt.

3. Remove the shift fork guide bar and shift forks. The shift forks are identified by numbers cast on their sides.

4.    Remove the neutral switch.

5.    Remove the bolt securing the shift cam locating pin and remove the stopper plate and locating pin.

1. Shift cam locating pin

6. Pull out the shift cam.

7. Remove the HY-VO chain tensioner and chain guide.