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
12. Cylinder head and Cam shafts
a. Install the new cylinder head gasket. Install the dowel pins and "O-rings". Locate the cam chain cavity cylinder seal with the tabs down.
b. Install the cylinder head onto the cylinder. Pull the cam chain through the cylinder head as it is installed. Tie the cam chain so that it does not fall into the crankcase.
CABLE ROUTING
Clamp the leads coming from the upper left hole with the left clamp and the leads coming from the upper right hole
with the right clamp. Keep the space between left and right leads couplers for the headlight coupler.
11. Pistons and Cylinder a. Install the pistons on the rods. The arrow on the piston must point to the front of the engine.
NOTE:
J. Oil Pump
1. Check the clearance between housing and outer rotor.
Standard clearance: 0.09 ~ 0.15 mm (0.0035 ~ 0.0059 in)
2. Check the clearance between outer rotor and inner rotor.
Standard clearance: 0.12 mm (0.005 in) or less
3. Check the plunger for scratches and wear.
Front fork disassembly
Warning:
Securely support the motorcycle so it won't fall over when the front wheel and fork legs are removed.
LUBRICATION DIAGRAMS
SHAFT DRIVE
Refer to "CHAPTER 3". for the middle gear.
The following special tools are not available but can be constructed for the final gear disassembly and assembly:
ELECTRICAL COMPONENTS
