TABLE OF CONTENTS
15.9
Checking the capacitor ..................... 139
15.10 Checking the starter relay ................. 140
16 BRAKE SYSTEM ........................................... 141
16.1
16.2
16.3
16.4
16.5
16.6
16.7
16.8
16.9
Checking the front brake linings ....... 141
Changing the front brake linings ....... 141
Checking the free travel of the
hand brake lever . . .. . . .. . .. . .. . .. . .. . .. . .. . .. . . 143
Adjusting the basic position of the
hand brake lever . . .. . . .. . .. . .. . .. . .. . .. . .. . .. . . 143
Checking the front brake fluid
level ................................................... 144
Adding front brake fluid .................... 144
Changing the front brake fluid .......... 146
Checking the brake linings of the
rear brake.......................................... 148
Changing the rear brake linings ........ 148
16.10 Checking the free travel of foot
brake lever . . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . .. . . 150
16.11 Adjusting the basic position of the
foot brake lever................................. 150
16.12 Checking the rear brake fluid level ... 151
16.13 Adding rear brake fluid ..................... 151
16.14 Changing the rear brake fluid ........... 153
17 ENGINE ......................................................... 155
4
17.1
17.2
17.3
17.3.1
17.3.2
17.3.3
17.3.4
17.3.5
17.3.6
17.3.7
17.3.8
17.3.9
17.3.10
17.3.11
17.3.12
17.3.13
17.3.14
17.3.15
17.3.16
17.3.17
17.3.18
17.3.19
17.3.20
Removing the engine ........................ 155
Installing the engine .......................... 162
Engine disassembly .......................... 170
Preparations................................. 170
Removing the clutch push rod ..... 170
Draining the engine oil. ................. 170
Removing the oil filter ................... 171
gear position sensor, removing .... 171
Removing the spark plug ............. 172
Removing the valve cover ............ 172
starter motor, removing ................ 173
Positioning the engine at
ignition top dead center ............... 173
Removing the timing chain
tensioner....................................... 17 4
Removing the camshafts .............. 17 4
cylinder head, removing ............... 175
Removing the piston .................... 175
Removing the rotor ....................... 176
starter drive, removing ................. 176
Removing the suction pump ........ 177
water pump impeller, removing .... 178
Removing the clutch cover ........... 178
Removing the clutch discs ........... 179
Removing the clutch basket ......... 179
17.3.21
Removing the primary gear
wheel ............................................ 180
17.3.22
timing chain, removing ................. 180
17.3.23
Removing the force pump ............ 181
17.3.24
Removing the locking lever .......... 181
17.3.25
shift drum locating unit,
removing ....................................... 182
17.3.26
Removing the shift shaft ............... 182
17.3.27
spacer, removing .......................... 182
17.3.28
Removing the left engine case ..... 182
17.3.29
shift rails, removing ...................... 183
17.3.30
Removing the shift drum .............. 183
17.3.31
Removing the shift forks .............. 184
17.3.32
Removing the transmission
shafts ............................................ 184
17.3.33
Removing the crankshaft ............. 184
17.4
Working on individual parts .............. 185
17.4.1
17.4.2
17.4.3
17.4.4
17.4.5
17.4.6
17.4.7
17.4.8
17.4.9
17.4.10
17.4.11
17.4.12
17.4.13
17.4.14
17.4.15
17.4.16
17.4.17
17.4.18
17.4.19
17.4.20
17.4.21
Working on the right section of
the engine case ............................ 185
Working on the left section of
the engine case ............................ 187
Work on the clutch cover . . .. . .. . .. . . . 188
Checking the oil pressure
control valve .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . .. 190
Checking the lubrication
system .......................................... 191
Removing the crankshaft
bearing inner race ......................... 191
Installing the crankshaft bearing
inner race ...................................... 192
connecting rod, conrod bearing,
and crank pin, changing ............... 192
Checking the crankshaft run-out
at the bearing pin ......................... 194
Measuring the crankshaft end
play ............................................... 195
Removing the drive gear wheel
of the balancer shaft..................... 195
Installing the drive gear wheel of
the balancer shaft ......................... 196
Cylinder - Nikasil
®
coating ........... 196
Checking/measuring the
cylinder ......................................... 196
Checking/measuring the piston ... 197
Measuring the piston/cylinder
mounting clearance...................... 198
Checking the piston ring end
gap ............................................... 198
camshafts, checking .................... 199
Checking the pivot points of the
camshafts..................................... 199
valves, removing .......................... 200
valves, checking ........................... 201
