C. Piston
1. Mark each piston to aid in reassembly.
2. Place a clean towel or rag into the crank-case to keep circlips and material from falling into the engine.
3. Remove piston pin clips, piston pins, and pistons.
D. Pick-up Coil Assembly
FRONT FORK
A. Removal and Disassembly
WARNING:
Securely support the motorcycle so there is no danger of it falling over.
ENGINE
A. Valve clearance adjustment
NOTE:
Valve clearance must be measured with the engine and at room temperature.
1. Remove the seat, fairing components, and fuel tank. See page 35.
2. Remove the horn, flasher relay, emergency engine stop relay and spark plug lead wires.
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.
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.
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
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:
ENGINE ASSEMBLY AND ADJUSTMENT
A. Important Information
1. Gasket and seal
All gaskets and seals should be replaced when an engine is overhauled. All gasket surfaces and oil seal lips must be cleaned.
2. Properly oil all mating engine and transmission parts and bearings during reassembly.
3. Circlip
D. Valve Spring and Lifters
1. Checking the valve springs
a.
This engine uses two springs of different sizes to prevent valve float
or surging. The valve spring specifications show the basic value
characteristics.
D. Remounting Engine
Refer to page 30 for engine removal. Reverse the applicable removal steps.
|— CAUTION:-------------------------------------------1
Always use new bolts in the drive shaft coupling.
2. Install and tighten the engine mounting bolts.