Crankcase Separation

Refer to Service information (page 11-2) for removal of necessary parts before disassembling the crankcase,

Remove the front cylinder cam chain.

Remove the left crankcase 8 mm flange, 6 mm small head and 8 mm socket holts.

ID FRONT CYLINDER CAM CHAIN

ID FRONT CYLINDER CAM CHAIN

Remove the hearing set plates rf the bearings are to be replaced

Hold the final driven shaft with a shaft holder and loosen the final drive shaft bolt.

11 ! SHAFT HOLDER

TOOL: Shaft holder

Remove the final drive shaft boit.

07923-6890101

11 ! SHAFT HOLDER

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?! FINAL DRIVE SHAFT BOLT

?! FINAL DRIVE SHAFT BOLT

Remove the rear cylinder cam chain.

Loosen, the right crankcase bolts in a crisscross pattern in 2 3

steps, and remove the bolts.

Place the crankcase with the right side down.

Separate the left crankcase from the right crankcase.

IT! REAR CYLINDER CAM CHAIN

IT! REAR CYLINDER CAM CHAIN

Remove the dowel pins end O-ring.

Remove the crankshaft, transmission, final driven gear, washer, shift forks, shift fork shaft end drum from the right crank-case.

Remove the output gear assembly from the left crankcase.

1(4) SHIFT DRUM (3) SHIFT FORK'SHAFT

1(4) SHIFT DRUM (3) SHIFT FORK'SHAFT

CRANKCASE ASSEMBLY

CI otto the left end nolo ctnnkcese tnstinp surfaces thoroughly, being careful not to damage them.

Install the output gear assembly in the left crankcase (page 11 -

Install the crankshaft, transmission,, shift forks and drum (p8Q6-

install the final driven gear thrust washer and gear in the right crankcase,

Apply lipoid sealant to the crankcase mating surfaces.

Install the dowel pins and a new O-ring.

install the left crankcase over the right crankcase, while inserting the output drive shaft into the final driven gear , washer and the case,

Tighten the fight crankcase bolts in the sequence shown in f1i REAR CYLINDER CAM CHAIN 2-3 steps,

TORQUE:

6 mm bohs 10 N-m (1.0 kg-m. 7.2 ft-ibl 8 mm bolts: 27 N-m |2.7 kg-m, 20 ft !b/

NOTE

Bolts 1 through 11 are 8 mm. After '94: holt 5 Is 10 mm.

install the rear cylinder cam chain.

15 X

Tighten the left crankcase bolts in 2 — 3 steps. TORQUE:

6 mm boit: 10 N-m (1.0 kg-m, 7.2 ft-ibl 8 mm bolts: 27 N-m (2.7 kg-m, 20 ft-ib)

Install the front cylinder cam chain.

Hi FRONT CYLINDER CAM CHAIN

Hi FRONT CYLINDER CAM CHAIN

(4) 8 mm SOCKET B0L.Tff(3) 6 mm SMALL HEAD BOLT

Apply locking agent to the final drive shaft bolt threads.. Hold the final driven shaft with the shaft holder, install and tighten the finai drive shaft bolt.

TOOL: Shaft holder

07923-6890101

;12! FINAL DRIVE SHAFT BOLT*

if the hearing set plates were removed, apply LOCTiTE'* to the bolt and screw threads and Install the set plates. Tighten the set plate bolts and screw,

llip w lis

CRANKSHAFT/CONNECTING ROD

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