Remove the cotter pins, knuckle nuts and washers. If not, set the clutch release outer guide in suitable position. Replace the removed O-ring with a new one to prevent leakage of fuel. Inspect the valve core, before installation. Install the drum cover and tighten the bolts.
Loosen the air bleeder valve and pump the brake lever until the old brake fluid is completely out of the brake system. Tighten the cylinder head cover bolts evenly and diagonally to the specified torque. Remove the bearings by tapping with the special tool and a hammer. Position the carburetor clamps as shown in the illustration. Tie rod ends tending to seize. Clean and degrease several teeth of the drive and driven bevel gears. Disconnect the brake hose from the brake hose clamp 2.
The oil should be changed while the engine is warm. Remove the coasting enrichment valve cover D and spring. Indicates a potential hazard that could result in death or injury. Remove the carburetor top cap. Replace the removed cotter pins with new ones. Hold the bearings with the special tool. If the clearance exceeds specification, replace the fork, its respective gear, or both.
Remove the reverse lock release cable A. Install the washers and cylinder head nuts M8 as shown. If the conrod small end inside diameter exceeds the service limit, replace the conrod with a new one. Noise seems to come from the crankshaft 1. Hold each piston ring with proper position, insert the piston into the cylinder. Tighten the locknut 2 to the specified torque while holding the adjusting screw 3.
This Service Manual has easy-to-read text sections with top quality diagrams and instructions. If any damages are found, replace the brake hoses with new ones. Remove the dust seals with the special tool. Remove the dowel pins and gasket. Apply engine oil to the conrod big end and gears. Fit the special tool onto the driveshaft.
Disconnect the - battery lead wire 1. Remove the shift cam lock shaft 5. Otherwise, the battery may be overcharged resulting in shortned service life. If any clearance reading exceeds the service limit, replace the cylinder with a new one. Remove the valve timing inspection plug 1 and generator cover cap 2. Remove the steering shaft holder bolts. Dismount the bead from the rim completely as shown.
Faulty ignition switch Faulty engine stop switch Faulty neutral relay Faulty neutral switch. . Pull out the carburetor from between the engine and air cleaner. Remove the exhaust pipe and gasket. Big-end bearing worn or burnt. Remove the cam chain tensioner 2.
Clean and degrease several teeth on the ring gear and pinion Incorrect gear, and then apply a coating of machinist s layout dye or paste to several teeth of the pinion gear. When the wear reaches the limit line, replace the pads with new ones. . If the runout exceeds the service limit, replace the valve with a new one. Air in brake fluid circuit. Step 1 1 Check accessories which use excessive amounts of electricity. Forward Loosen the locknuts 1, 2 on each tie rod.
. Press the air cleaner element between the palms of both hands to remove the excess solvent: do not twist or wring the element, or it will tear. If any damages are found, replace them with new ones. Remove the coasting enrichment valve E. They are specifically written for the do-it-yourselfer as well as the experienced mechanic. Install the new O-ring A onto the oil filter fitting boss of the clutch cover. Swingarm type, coil spring, oil damped Front wheel travel.
Check that all chassis nuts and bolts are tightened to their specified torque. Ignition coil resistance Terminal 0. Remove the bearing with a commercially available bearing puller or a hydraulic press. The removed bearing must be replaced with a new one. Install the gearshift forks and shafts as shown. Slide the adjuster 2 until the cable play at the reverse lock release knob A reaches 1 2 mm 0.