SHIFTER AND MIDDLE GEAR
1. Remove:
• Crankcase cover (Left) 1
• Gasket
• Dowel pin 2
• Shift shaft 3
• Shift lever 4
• Oil level maintaining plug 5
2. Remove:
PISTON AND CYLINDER
1 Cylinder head gasket
2 Dowel pin
3 Drain bolt
4 Oil delivery pipe
5 O-ring
6 Cylinder base gasket
7 Piston ring
8 Piston pin clip
9 Piston pin
10 Copper washer
1. Install:
• Piston rings (onto the pistons)
STARTER MOTOR
SPARK PLUG
1. Remove spark plugs
2. Inspect:
• Electrode (1) for wear/damage.
• Insulator color (2)
3. Measure the plug gap (3) using a Wire Gauge or Feeler Gauge. Regap as reqired.
Plug Gap: 0.6 - 0.7 mm (0.024 - 0.028 in)
HEADLIGHT
Headlight Bulb Replacement
1. Remove securing screws (1) from light unit assembly/headlight body.
2. Disconnect the headlight lens unit leads
3. Remove the light unit assembly
CLUTCH
1. Inspect:
• Clutch housing dogs 1
Cracks/Pitting (edges): Moderate -> Deburr.
Severe -> Replace clutch housing.
2. Inspect
• Clutch housing bearing 2
• Spacer 3
CAMSHAFT
FRONT BRAKE
Brake Fluid Inspection
1. Check the Brake fluid level. Replenish as required.
NOTE:
Use only DOT 3 or equivalent fluid from a sealed container.
CLUTCH ADJUSTMENT
1. Loosen the adjuster locknut (1)
2. Adjust the clutch lever free play (a) by turning adjuster (2) in or out.
Free Play (a): 2 - 3mm (0.08-0.12 in)
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)
