5. Clutch assembly
a. Install the thrust plate onto the transmission main axle.
1. Thrust plate
b. Install the oil pump drive sprocket onto the main axle without the spacer collar and place the oil pump drive chain on its sprocket.
1. Oil pump drive sprocket
Submitted by xjcdadmin on Thu, 04/23/2009 - 14:15ENGINE OVERHAUL
A. Cylinder Head and Cylinder
1. Remove the cylinder head cover.
2. Remove the left crankcase cover (pickup coil cover).
3. Remove the cam chain tensioner.
2. Lower crankcase
a. Install the shift cam and secure it with the guide pin. Install the stopper plate and bolt and tighten securely.
b. Install the neutral switch.
c. Install the transmission drive axle assembly into the crankcase.
13. Remove the front cylinder holding nut and remove the cylinder assembly. It may be necessary to tap the cylinder lightly to loosen it from the base gasket.
14. Remove the rear cam chain guide by loosening the holding bolt.
Submitted by xjcdadmin on Thu, 04/23/2009 - 14:15
C. Middle Gear Servicing
1. Disassembly
Refer to page 39 for disassembly.
2. Inspection
Refer to page 52 for inspection.
3. Gear lash check
NOTE:
Submitted by xjcdadmin on Thu, 04/23/2009 - 14:15L. Lower Crankcase
1. Remove the dowel pin and "O-ring".
2. Remove the shift fork guide bar and shift forks. The shift forks are identified by numbers cast on their sides.
3. Remove the bolt securing the shift cam locating pin and remove the stopper plate and locating pin.
Submitted by xjcdadmin on Thu, 04/23/2009 - 14:15L. Transmission
1. Inspect each shift fork for signs of galling on gear contact surfaces. Check for bending. Make sure each fork slides freely on its guide bar.
2. Roll the guide bar across a surface place. If the bar is bent, replace.
Submitted by xjcdadmin on Thu, 04/23/2009 - 14:158. A.C. Generator
a. Install the rotor onto the shaft and tighten the bolt using the rotor holding tool (special tool) as shown.
1. Rotor holding tool
Tightening torque: 5.5 m-kg (39.8 ft-lb)
b. Install the stator coil assembly onto the crankcase and align the grooves on the stator core with the bolt holes on the crankcase.
Submitted by xjcdadmin on Thu, 04/23/2009 - 14:15H. Oil Pump Removal and Disassembly
1. Remove the strainer cover. Note the wire harness clip position.
2. Remove the oil pump securing bolts and remove the sprocket cover and oil pump assembly.
CAUTION:
Submitted by xjcdadmin on Thu, 04/23/2009 - 14:15INSPECTION AND REPAIR
A. Cylinder Head Cover
Place head cover on a surface plate. There should be no warpage. Correct by re-surfacing as follows:
Place #400 or #600 grit wet sandpaper on surface plate and re-surface head cover using a figure-eight sanding pattern. Rotate head cover several times to avoid removing too much material from one side.
Submitted by xjcdadmin on Thu, 04/23/2009 - 14:15