15 ENGINE 18 Preparatory work = Raise the motorcycle with a lift stand. (#* p. 10) = Remove the seat. (* p. 53) = Turn the knurled screw on the fuel tap all the way clockwise. = Dismount the fuel tank. (¥ p. 53) = Drain the coolant. (* p. 128) — Remove the exhaust manifold, (** p. 48) Main work = Loosen the hose clamps. Detach the radiator hoses. = Remove screws @. — Remove screw @. = Remove the clutch slave cylinder and hang it to one side. © Info Do not kink the clutch line. Do not pull the clutch level while the clutch slave cylinder is removed ~ Remove serew @ = Disconnect spring @. ~ Remove screw @ = Maneuver te foot brake pedal out toward the rear, = Pull off the spark plug connector. = Disconnect plug-in connector @. = Remove screns @. = Take off the ignition coil, = unscrew hose clip @ = Pull the carburetor out ofthe intake flange toward the rer,15 ENGINE 73 ~ Remove serous @ ~ Remove screw @. = Toke of the engine sprocket cove. = Remove screw @. = Toke off the shift lever. = Remove connecting lnk (B ofthe chain. = Remove the chain = Remove nuts @. = Remove both screws = Remove nut ®. = Remove the swingarm pivot. = Lift out the engine from the side Info Tut the tink fork back slightly. It is useful to have an assistant help you with this step. Ensure that the motorcycle is well-secured against falling over. Protect the frame and attachments against damage. Main work = Position the engine in the frame, = Mount the swingarm pivot.15 ENGINE 80 ~ Mount the scraws wit nuts @, but co not tighten them yt. = Mount and tighten nut @. Guideline ‘Nut, swingarm pivot Midi 40 Nm (29.5 tof fo) = Tighten nuts @ Guideline Screw, engine bracket Me 30 Nm (22.1 tbf FO = Position the fot brake lever = attach spring ©. = Mount and tighten screw @. Guideline ‘Screw, foot brake lever | M10 35Nm Loctite® 243 (25.8 Ibe ft) = Mount and tighten screw @ Guideline Screw, ball joint of push rod on foot [ M6 10 Nm (7.4 bt FD) brake cylinder ~ Postion the clutch slave cylinder withthe seal = Mount and tighten screws @. Guideline Screw, clutch slave cylin- | M6 10.Nm Loctite® 243 der (7A tbr A) = Position the clutch line with the holder. = Mount and tighten screw Guideline Screw, clutch line holder oy 5 Nm (3.7 Wot A) = Position the ignition coll Mount and tighten screw @ with the ground wire. Guideline Remaining screws, chassis Me 10 Nm (7.4 bt FO) = Mount and tighten screws @. Guideline Remaining screws, chassis Me 10 Nm (7.4 Ibtf) = Connect the plug-in connections @. = Mount the spark plug connector.15 ENGINE = Mount the chain = Connect the chain wth connecting tink @. = Position the shift lever = Mount and tighten screw @B with the washers Guideline ‘Screw, shift lever Me T4Nm Toctite® 243 (10.3 Ibe ft) = Position the engine sprocket cover. = Mount and tighten screw @®. Guideline Screw, engine sprocket cover Me TONm (7.4 lot) ~ Mount and tighten screw @ Guideline Remaining screws, chassis ue 25 Nm (18.4 tof) = lie the carburetor into the intake nee ~ Position an tigten hose clamp @. ~ Mount the radiator hoses. Position and tighten the hase clamps. = Install the exhaust manifold. (7 p. 48) = Remove srew cap € and fill up with gear il Gear oll 0.50 1(0.53 gt) _| Engine oil (15W/50) (# p. 150), = Mount and tighten screw cap @®. = Refill the coolant. (* p. 128) Finishing work Install the fuel tank. (€ p. 54) = Mount the seat. (* p. 53) = Remove the motorcycle from the lft stand. (# p. 10) = Make a short test ride. = Check the engine for leakage. = Check the gear oil level. ( p. 131) = Check the coolant level. (** p. 129)15 ENGINE 82 15.3.1 Clamping the engine into the engine work stand = Mount special toot @ on engine work stand @ Engine assembly stand (61229001000) (* p. 158) Holder for engine assembly stand (46229001070) (* p. 155) = Mount the engine. Fitting for engine assembly stand (46229001060) (* p. 155) 15.3.2 Removing the clutch pressure piece = Remove the clutch pressure piece @. = Remove the oil drain plug with magnet @ and the seal ring. = Completely drain the gear ol = Remove spark plug @. Spark plug wrench (60029073000) (* p. 158) = Remove screns @. Take off the diaphragm cover of the exhaust control. 7 |15 ENGINE 15.3.6 Removing the cylinder head r Pall up the diaphragm. Hold shat ofthe exhaust control. Remove nut @. Remove the diaphragm. Remove screws @ Remove the reed valve housing of the exhaust control. Remove sing @. Remove O-ings @. Alternately loosen screws @ and remove them, Take ofthe cylinder head. Remove the cylinder head gasket. Remove the dowel pins.15 ENGINE Removing the exhaust control valve ~ Remove exhaust contol vee @ 15.3.8 Removing the cylinder = Remove nuts @ on both sides, Info Te careful nat to misplace the clutch line holder. = Carefully slide the cylinder up and take it off Take off the cylinder base gasket. — Remove the dowels. = Remove piston pin retainer = Remove the piston pin ~ Take off the piston. ~ Remove the upper conrod bearing @. = Remove lock ing @. Takeoff the engine sprocket15 ENGINE 85 15.3.11 Removing the spacer ~ Remove spacer @ of the countershat, = Remove Oving @. = Remove screws @. Remove the alternator cover. ~ Hola the rtor in place with special too! @. Holding spanner (54629012100) (* p. 157) ~ Remove nut @ withthe washer. = Mount special too! @, apply counterprssure, and pul off the rotor by screwing in the scr. Extractor (54629009044) (* p. 157)15 ENGINE 15.3.14 Removing the stator Remove cable support sleeve @ out ofthe engine case Remove srew @ Toke out the stator. Remove screw @ with the washer. Take off the kickstarter. Remove screws @ Take off the water pump cover. Remove the gasket and dowels. Remove screws @. Take off the clutch cover. Info T Ensure that the kickstarter shaft remains in the engine case. Remove the dowels and clutch cover gasket. Hold the clutch in place with special toot @. Clutch holder (49012003000) (* p. 156) Remove screw @ Remove the clutch pack.15 ENGINE 8 = Remove washer @. Hold the outer clutch hub in place with special tool @. Gear segment (46229081000) (* p. 156), Loosen nut @ of the primary gear and remove it with the washer. $300777-10 Take off the outer cluten hub. ~ Remove needle bearing @ and colar bushing @ Takeoff primary gear @ Remove the woodtu key. = Remove the washer,15 ENGINE 15.3.20 Removing the kickstarter shaft Detach hctstater spring @. Remove kickstarter shatt Q. Info TH turn the kickstarter shaft slightly to the left = Remove washer @. 15.3.21 Removing the intermediate kickstarter gear Remove lock ring @. Take off intermediate kickstart gear @ with the washer Remove screw © Remove the retaining bracket. Push siding plate @ away trom te sit drum locating @. Remove sit shaft @ withthe washer. Remove screw @ Press locking lever @ away from shift drum locating @ and take off the shift drum locating. Release the locking lever Remove screw @. Take of locking lover @ withthe sleeve and spring15 ENGINE 15.3.25 Removing the reed valve housi ing. ~ Remove serens @ = Takeoff the intake flange = Remove reed vee housing @. = Remove the gaskel section = Remove screws @ = Swing the left section of the engine case up and remove the screw connection of the engine holder. = Mount special too! @. Protecting sleeve (46229090000) (* p. 156) = Mount the special tool Extractor (45225048000) (* p. 154) © Info Huse the hote labeled 462. = Separate the engine case sections by screwing in screw @. © Info I Ensure that the engine case section is raised evenly. = Take off the left section of the engine case. = Remove the special tools,15 ENGINE ~ Remove engine case gasket @. = Remove shift rails @ with the springs. ~ Swing shit orks @ to onesie Info Take sure not to misplace the shift rollers = Remove sit dum @ Take shift forks @ out of the shift grooves. i Info Make sure not to misplace the shift rollers. 15.3.30 Removing the transmission shaft ~ Pull both transmission shatts @ out ofthe bearing sat together. Info I The stop disks ofthe transmission shatts usualy stick to the bearings15 ENGINE 15.3.31 Removing the crankshaft Warm up the crankshaft bearing Guideline 60°C (40°F) Remove crankshatt @. Remove O-ring @. Pall the dowels out ofthe engine case. Remove crankshatt sel rine @). Remove bearing retainer @. Remove bearing retainer @. ‘Warm the engine case section in an oven. Guideline 150°C (027) Knock the engine case section against level wooden plate, This wil cause the bearings to dropout of the bearing seats. Info Any bearings that remain in the engine case section must be removed using 2 suitable tool. Insert the new cold bearings into the bearing seats of the hot engine case section and, if necessary, use a suitable press drift to push the bearing from the inside to the outside, all the way to the stop or so itis flush. © Info Bearing @ of the water pump must be pressed from the outside to the inside so itis flush. When pressing the bearing in, ensure that the engine case section is level to prevent damage. Only press the bearings in via the outer ring; otherwise, the bearings will be damaged when they are pressed in, Press crankshatt seal ring @ from the outside to the inside with the open side fac- ing inward. © Info The shaft seal ring must be flush on the outside. ‘Mount bearing retainer @. Guideline Screw, shift drum bearing | M6 SNM Loatte® 648™ retainer (3.7 FD15 ENGINE 2 ~ Mount bearing retainer © Guideline Screw, main shaft bearing | MB Nm Tet 46 retainer (rier 15.4.2 Work on the left section of the engine case = Pull the dowels out of the engine case. = Remove crankshaft seal ring @. = Remove shaft seal ring @ of the countershaft, = Warm the engine case section in an oven, Guideline 150°C (302 °F) = Knock the engine case section against @ level wooden plate, This will cause the bearings to drop out of the bearing seats. Into TAny bearings that remain in the engine case section must be removed using 2 suitable tol Insert the new cold bearings into the bearing seats of the hot engine case section and, if necessary, use a suitable press drift to push the bearing from the inside to ‘the outside, all the way to the stop or so itis flush, i Info ‘Wen pressing the Bearing in ensure that the engine case section is lvl to prevent damages 7 Only press the bearings in via the outer ring; otherwise, the bearings will be damaged when they are pressed in. = Press crankshaft seal ring @ from the outside to the inside = Press shaft seal ring @ of the countershaft from the outside to the inside with the ‘open side facing inward. i Info The shaft seal rings must be flush on the outside. 15.4.3 Changing the connecting rod, conrod bearing, and crank pin Main work = Posi Press plate (46229047050) (* p. 156) = Position the crankshaft in the press with the special tool = Press the crank pin out of the upper crank web with a suitable push-out drift Info Told the tower crank web. nspecil too! @ between the crank webs = Take off the connecting rod, bearing, and stop disks. = Press the crank pin out of the crank web.15 ENGINE Position the crank web with the special tool, ‘Anchor plate (46229047002) (* p. 156) — Press the new crank pin @ all the way in. = Mount stop disks @, bearing, and connecting rod @. Info Toit the bearing thoroughly. ~ Position special tool @ onthe press, Pressing device, crankshaft, complete (50329047000) (* p. 157) ‘Anchor plate (46229047002) (*" p. 156) Bushing, crankshaft pressing device (46229008001) (* p. 155) = Insert the crank web with the connecting rod and bearing. ~ Position the second crank web. = Position special too! @ with the offset facing down. Cover, crankshaft pressing device (46229008002) (* p. 155) = Press the upper crank web all the way Info ‘The press mandrel must be applied above the crank pin. Take the crank web out of the special tool and check that the connecting rod can move freely ~ Measure axial clearance @ between the stop disk and the crank webs with the ‘special tool. Feeler gauge (59029041100) (*" p. 158) Connecting rod - axial clearance of |_| 0.40....0.75 mm (0.0157... lewer conrad bearing 0.0296 in) » Ifthe specifications are not met: = Correct the axial clearance to the specified value. Finishing work = Check the crankshaft run-out on the bearing pin. ( p. 94)15 ENGINE 15.4.6 Installing the water pump 15.4.4 Checking the crankshaft run-out on the bearing pin = Position the crankshaft on a roller block. = Turn the crankshatt slowly. = Check the crankshaft run-out on both bearing pins. £0.03 mm (0.0012 in) Crankshaft - run-out on bearing pin » Ifthe crankshaft run-out on the bearing pin is larger than the specification: = Align the crankshaft. = Remove water pump drive gear @. ~ Hold shaft @ in place and remove screw @ = Toke of the water pump impel. Info I isthe water pump impeller cannot be removed, the water pump shaft can be pressed out toward the inside = Remove water pump shatt @. = Remove shaft seal ring @. = Press out the bearing of the water pump shaft with a suitable tool. i” ‘Support the clutch cover when pressing out. = Press in the bearing of the water purmo shaft with a suitable tool so itis flush. Info TH support the clutch cover when pressing in. ~ Press shat seal ring @ all the way in.15 ENGINE 15.4.7 Checking/measuring the cylinder 20082010 ‘Mount water pump shatt @. Info To not damage the shaft seal ring. ‘Mount the water pump impeller. Mount and tighten screw @. Guidetine Screw, water pump wheel | M5 5 Nm Loctite® 243 (3.7 tbr fh) Mount drive gear @. ‘Check the eylinder bearing surface for damage. » Ifthe cylinder bearing surface is damaged: = Change the cylinder and piston. Measure the cylinder diameter at several locations on the @ anc @@ axes using a micrometer to check for oval wear. Guideline Cylinder - bore diameter ‘Size A 45,025... 45,037 mm (1.77263. 1.77311 in) Size B 45,037... 45,050 mm (1.77311... 1.77362 in) The ylinder size @ is labeled onthe side ofthe cinder ‘Check the piston bearing surface for damage. » Ifthe piston bearing surface is damaged: = Change the piston and, if necessary, the cylinder. Check that the piston ring moves smoothly in the piston ring groove. » Ifthe piston ring is stiff: = Clean the piston ring groove. Tip TH Use an ota piston ring to clean the piston ring groove. ‘Check the piston ring for damage. Ifthe piston ring is damaged:15 ENGINE = Change the piston ring. ‘Check the piston ring anti-otation lock for damage and to ensure that itis firmly seated > Ifthe piston ring anti-rotation lock is damaged or loose: = Change the piston, ‘Check the piston pin for discoloration or signs of wear. » Ifthe piston pin has strong discoloration/signs of wear: — Change the piston pin with the piston pin bearing, ‘Check the piston pin bearing for damage and weer. » If there is damage or wear: = Change the piston pin bearing and connecting rod, if necessary. ‘Measure the piston at a distance @ from the piston head, at right angles to the piston pin. Guideline Distance @ 32.0 mm (1.26 in) Piston - diameter ‘Size 1 44,955... 44.965 mm (1.76988... 1.77027 in) ‘Size 2 44,965... 44.975 mm (1.77027... 1.77067 in) Piaton size @ is marked onthe piston hea 15.4.9 Determining the piston/cylinder mounting clearance = Checkimeasure the cylinder. ( p. 95) = Determine the piston/eylinder mounting clearance. (** p. 96) = The smallest pistonfeylinder mounting clearance is the result of the smallest cylinder bore diameter minus the largest piston diam- eter. The largest piston/cylinder mounting clearance is the result of the largest cylinder bore diameter minus the smallest piston diameter, Guideline Piston/eylinder - mounting clearance New condition (0.066... 0.085 mm (0.00236... 0.00335 in) Wear limit {0.10 mm (0.0039 in) 15.4.10 Checking the piston ring end gap Remove the piston ring from the piston Pace the piston ring in the cylinder and align it with the piston, Guideline Under the upper edge of the cylinder | 10 mm (0.39 in) Measure the end gap @ using a feler gauge. Guideline 400542:10 Piston ring end gap *€.0.60 mm (= 0.0236 in) » Ifthe end gap is more than the specified value: = Checkimeasure the cylinder. (* p. 95) > Ifthe cylinder wear is within the tolerance range: = Change the piston ring.15 ENGINE 27 154.11 Checking the eed valve housing, diaphragm and intake flange = Check eed valve housing @ for damage and wea. > Hf thee is damage or wear: = Change the red valve housing. — Check the diaphragm for damage and wear. We there is domage or wear — Change the diaphragm. ~ Check intake lange @ for damage and wear. > Hf there is damage or wear: = Change the intake lange. = Remove screws @. = Take off the spring retainer. = Remove the springs. ~ Take oft inne clutch hub @. = Take off clutch discs @ from the clutch pressure cap.15 ENGINE 154.13 Checking the clutch ~ Check pressure piece @ for demage and wear. there is damage or wear ~ Change the pressure piece. ~ Check the length of clutch sorings @ Clutch spring - length 21,5... 21.9 mm (0.846... 0.862 in) » If the clutch spring length is less than the specified value: = Change all clutch springs. = Check the contact surface of inner clutch hub @ for damage and wear, >If there is damage or wear: = Change the inner clutch hub. ~ Check the contact surfaces ofthe clutch facing diss in outer clutch hub @) for weer. Contact surface, clutch facing discs in| = 0.5 mm (= 0.02 in) outer clutch hub > tthe contact surge is very wom = Change te clutch facing discs andthe outer clutch hub ~ Check needle bearings @ and collar bushing @) for damage and wear. 2 Hf there is damage or wear = Change the needle bearing and collar bushing ~ check intermediate discs @ for damage and wea. + the intermesiate dies are not level and have pttings: = Change all clutch discs. = Check elute facing dises @ tor ciscoloration and scoring. + Ifthe is discoloration o scoring: = Change all lutch facing dics. = Check the thickness of clutch facing discs @ 200805-01 Clutch facing disc - thickness 1.8mm 0.071 in) » If the clutch facing disc does not meet specifications: = Change all clutch facing discs. ~ Check clutch pressure cap @ for damage and wear. » there is damage or wear: = Change the clutch pressure cap. = Check spring retainer @ for damage and wear. > If there is damage or wear: = Change the spring retainer. 154.14 Premounting the clutch = Oil the clutch dises well = Beginning with a clutch facing disc, positon al further elute facing dses and intermediate diss on inner clutch hub @.15 ENGINE = Mount euten pressure cap @. = Position the springs. ~ Position spring retainer @ ~ Mount serews @, but do nat tighten them yet. = Check shitt forks @ on leat @ for damage and wear (visual inspection). > Ifthere is damage or wear: = Change the shift fork and gear wheel pair. = Check shift grooves @ of shift drum @ for wear. >If the shift groove is worn: = Change the shift ole. = Check the seat of the shit drum in bearings @). » Ifthe shift roller isnot seated correctly: = Change the shift drum andlor the bearing ~ Check bearing @ for smoeth operation and wear. >» Ifthe bearings do not move frely or are worn: = Change the bearings. = Check shift rollers @ for smooth operation in the shift groove and for wear » Ifthe shift roller does not move freely or is worn: = Change the shift roller. = Check springs @ of the shift rails for darnage and wear, Ifthe spring is broken or worn = Change the spring ofthe shit al. = Check shift rit @ on a flat surface for tun-cut. > I thereis run-out = Change the shitt ral = Check the shift rail for scoring, signs of corrsion, and stiffness inthe shift forks. If there is scoring or coresion, or if the shift fork is tt = Change the sift ail.15 ENGINE 100 Check slicing plate @ in contact area @ tor wear: Ifthe sliding plate is wor: = Change the sliding pate. Check return surtace @ on the sliding plate for wear + deep notches are present = Change the sliding plate Check guide pin @ for looseness and wear. 2 Ifthe guide pin i lose andlor worn: = Change the sliding plate. reassemble the shift shat. p. 100) Check clearance @ between the sliding plate and shift quacrant. ‘Shift shaft - play in sliding plate/shift | 0.40... 0.80 mm (0.0167... quadrant 0.0315 in) 400372-11 >If the measured value does not equal the specified valve: = Change the sliding plat. Fix the short end of the shift shaft in a vise Guideline Use soft jaws, ‘Mount preload spring @. Push on spring guide @, push return spring @ over the spring guide with the offset end facing upward and lift the offset end over abutment bolt @. Mount washer @. Mount lock ring @. Mount stop disk 300800.01 Fix the main shaft in the vise with the geared end facing downward, Guideline Use soft jaws. ~ Remove stop disk @) and 2nd-gear fixed gear @. = Remove 6th-gear idler gear @. = Remove lock ring @ = Remove 3c/ath-gear slicing gear = Remove lock ring @. — Remove Sth-geariater gear @15 ENGINE 15.4.18 Assembling the main shaft 101 Info Use now lock rings in every repair job. Preparatory work = Cilall parts carefully before assembling. = Check the transmission. (** p. 102) 0800.02 work = Fix the main shaft in the vise with the geared end facing downward, Guideline Use soft jaws = Mount Sth-zear idler gear @ withthe shift dogs facing up. ~ Mount lock ring @. ~ attach Srd/ath gear slicing gear @ withthe small gear wheel facing up and mount lock ring @ ~ Mount éth-gear idler gear @ withthe shit dogs facing down. = Attach 2nd-gar teed gear @ and stop disk @ = Finally, check all gear wheels for smooth operation. 15.4.19 Dismantling the countershaft 300801.01, — Fix the countershaft in the vise with the geared end facing downward. Guideline Use soft jaws ~ Remove stop disk @) and Ist-gear ater gear @ ~ Remove needle bearing @. ~ Remove Sth-gear sliding gear @ and lock ring @. ~ Remove 4th-gear idler gear @. = Remove 3rd-gear idler gear @. ~ Remove lock ring © ~ Remove 6th gear sliding gear @. = Remove lock ring @. = Remove 2nd-gear idler gear @.15 ENGINE 15.4.20 Assembling the countershaft 102 Info Use now lock rings in every repair job. Preparatory work = Cilall parts carefully before assembling. = Check the transmission. (** p. 102) es sooso.ce work = iv the countershat in the vie withthe geared end facing downward, Guidetine Use soft ians = Mount 2ng-ger iaer gear @ on the countershatt wit the protruding collar facing down, = Mount lock rng @. — Mount 6th-gear slicing gear @) withthe shift groove facing up ~ Mount ck ring @. = Mount 3r8-gar iter gear @ wit te collar facing up ~ Mount dth-gar idler gear @ with the collar facing down. = Mount lock ring @. ~ Mount Sth-zear sliding gear @ withthe shift groove facing down. ~ Mount needle bearing @, 1st-ger idler gear QD withthe cut-out facing down, and stop ask @D. = Finally, check al gear wheels for smooth operation. 154.21 Checking the transmission Concition ‘The transmission has been disassembled,15 ENGINE 300802.01 = Check needle bearings @) for damage and wear > Hf there is damage or wea: = Change the needle bearings = Check the pivot points of main shatt @) and countershatt @ for damage and wea. > I there is damage or wea = Change the main shaft and/or countershat = Check the tooth profiles of main shatt @ and counteshatt @ for damage and wear. Ht there i damage or wear = Change the main shat and/or countershat ~ Check the pivot points of idler gears @ for damage and wer. > Hf thare i damage or woa: = Change the gear whee! pair, Check the shift dogs of idler gears @ and sliding gears @ for damage and wear. > He there is damage or wear = Change the gear wheel par, ~ Check the tooth faces ofthe idler gears @, sliding gears @ and fied gear @ for damage and wear > Hf there is damage or wea: = Change the gear wheel pair, = Check the tooth profiles of sliding gears @ for damage and wear. > Hi there is damage or wea = Change the gear whee par ~ Check sliding gears @ for smooth operation inthe rofleof main shatt @ > Ht the slicing gear i tt: = Change the siding gear or main shat. ~ Check sliding gears @ for smooth operation inthe profile of countershatt @ Hf the slicing gear i st ~ Change the sling gear or countershatt. ~ Check stop disk @ for damage and wear. > Hi there is damage or wear = Change the stop disk = Use new lock rings @ whenever making repairs. 10315 ENGINE 108 154.22 Premounting the kickstarter shaft = Mount kickstater ratchet wheel @. Marking @ is offset from hole @ by 180°. = Mount washer @ Mount starter wheel @. = Mount washer @ and lock ri ~ Position the spring and hook it into hole @ = Mount driving hub @.15 ENGINE 105 15.5.1 Installing the crankshaft = Position the right section of the engine case in the engine work stand, Engine assembly stand (61229001000) (= p. 158) Holder for engine assembly stand (46229001070) p. 158), Warm up te erenishaft bearing Guiding 60°C (1407) ~ Slide crankshat @ all the way into the bearing seat ofthe right section ofthe enaine case. = Mount the dowels, 15.5.2 _ Installing the transmission shafts = Oilall bearing. Engine oll (15W/50) (* p. 150) = Assemble the two transmission shafts @ and side them into the bearing eats together, 15.5.3 Installing the shift forks = Arrange the shift forks as shown, ~ Position shit forks @ in the shit groves. 15.5.4 Installing the shift drum Slide shift drum @ into the bearing sat Attach shit orks @ to te sit drum. © Info Make sure not to misplace the shift rollers.15 ENGINE 106 15.5.5 Installing the shift rails ~ Install shit rats @ together withthe upper and lower springs. Ti Fox the springs in the shift rails with grease. 15.5.6 _ Installing the left engine case section = Mount engine case gasket @. ~ Check that dowels @ are seated correctly. — Warm up the crankshaft bearing ofthe left section of the engine case. Guidetine 60°C 140" = Mount the left section of the engine case, Strike lightly with a rubber mallet if nec essary. © Into To not tighten the engine case sections using the screws = Mount screws @ ard tighten them ater ll screws of the left engine case section are mounted. Guideline Seren, engine case Mees TONM TATED ~ Mount screws @ and tighten thom afterall screws ofthe left engine case soction are mounted Guideline Seren, engine case MEAD TONm (74 FAD = Mount screws @ and tighten al screws in a crisscross pattern. Guideline (Screw, engine caso ——~=~S~*~*~*~CGS~S~*~LON ATO = Fix the engine in the engine work stand, 15.5.7 _ Installing the reed valve housing = Position the gasket. ~ Position red vale housing @ in the engine case opening.15 ENGINE 107 = Position the intake flange. = Mount and tighten screns @. Guideline Soren, intake Tlangveed valve housing [ ME TON aI TD ey Ss '300790-11 15.5.8 Installing the locking lever ~ Position locking lever @® with sleeve and spring @. = Mount and tighten screw Guidetine ‘Screw, shift drum locating | M5 6 Nm Loctite® 243 (4.4 tbr ft) 15.5.9 Installing the shift drum locating Press locking lever @ down and position shift drum locating © nfo T The tat surfaces @ of the shift drum locating are not symmetric. = Release the locking lever. = Mount and tighten screw Guideline ‘Screw, shift drum locating | M6 10Nm Toetite® 243 (7. tbe fo) ~ Slide shttshatt @ withthe washer into the bearing seat = Push sliding plate @ away trom the shit drum locating @. Inset the shift shaft all the wa. = Let the sliding plate engage in the shift drum locating = Shift though the transmission.15 ENGINE 108 15.5.11 Installing the intermediate kickstarter gear ~ Position intermeciate kickstart gear @ with the washer = Mount feck ring @. = Pesition the retaining bracket = Mount and tighten screw @. Guideline ‘Screw, retaining bracket | M5 Nm Toctite® 243 for return spring of shift (4.4 tbr ft) shaft 15.5.12 Installing the kickstarter shaft = Premount the kickstarter shaft. (7 p. 104) = Mount the premounted kickstarter shaft @ with the washer, ~ Hook in kickstarter spring @. = Position the O-ring = Moun washer @ = Mount woodrut key @ ~ Position primary gear @ = Mount cellar bushing @ and needle bearing @15 ENGINE ‘Mount the outer clutch hub. Hold the outer clutch hub in place with special tool @. 108 Gear segment (46229081000) (+ p. 156), ‘Mount and tighten the washer and nut @ of the primary gear. Guideline ‘Nut, primary gear Mi4x125 | 40Nm (29.5 lof ft) Toctite® 243 Mount washer @. remount the clutch (Fp. 98) Pesiton the clutch pack Hols the clutch in place with special tot @ Clutch holder (43012003000) (* p. 156) ‘Mount and tighten screw @. Guideline ‘Screw, inner clutch hub mio 60 Nm (44.3 Ibe ft) Loctite® 243 Tighten screws @. Guideline Ne ‘Screw, clutch springs 10 Nm (7.4 Ibt fd) Mount dowels @ Mount clutch cover gasket @.15 ENGINE ~ Postion the clutch cover. Mount an tighten screws @ 10 Guideline Screw, clutch intermediate cover Me TO Nn (7.4 TF FD © Info Do not forget the spring hanger. ~ Mount the gasket and dowels. = Position the water pump cover. = Mount and tighten screws @. Guideline Screw, water pump cover Me Nm 63 bt = Position the kickstarer. Mount and tighten screw @ with the washer Guideline Screw, kickstartar mB 25 Nm Loette® 243 (28.4 torte ~ Position the stator. = Mount screws @, but do not tighten ther yet. Guideline Screw, ignition Me Nm Loette® 222 systervistator (3.7 br #9 ~ Position cable support sleeve @. ~ Ensure that the woodrulf key is seated properly = Grease the cone = Mount rtor @.15 ENGINE Oo fa 15.5.21 Installing the cylinder mt Hold the rotor in place with the special tool Holding spanner (54629012100) (* p. 157) ‘Mount washer and nut @. Tighten the nut, Guidetine Nat, rotor MI2x1 50 Nm (36.9 tof f) Oil the upper conrad bearing and positon it inthe connecting rod. Position the piston wo Piston marking @ must face the exhaust side. Slide piston pin @ nto the connecting tod by hand, Cover the engine case opening with a cloth. Position the piston pin retainer in the 6 o'clock or 12 o'clock position. Ensure that the piston pin retainer is correctly seated on both sides. Remove the clath. ‘Mount the dowels. Position the new cylinder base gasket. Info Tir neither the piston, cylinder, crankshatt or engine case need to be changed, the same gasket thickness can be used as before. Oil the cylinder and piston, Position the piston ring, Y The anti-otation lock engages in piston ring end @. Slide the cylinder over the piston Push the cylinder down carefully and let the dowels engage.15 ENGINE 12 = Mount nuts @ on both sides and tighten in a erissross pater. Guideline ‘Nats, cylinder base ue 20 Nm (14.8 tof Info Te careful not to forget the clutch line holder. 155.22 Checking the X-distance © Info The x-aistance is the distance defined for the piston protrusion, when the cylinder is clamped down and the piston is at top dead center. ‘The X-distance must be checked very carefully. Ifthe X-distance is too large, the compression decreases and the engine loses Power. If the X-distance is too small, the engine knocks and overheats. ~ Aply special too! @ tothe cylinder. Adjustment gauge (46129006100) (* p. 154) = Info T Appiy the special too! with abel eylinder height onto the cylinder. Position the piston at top dead center. = Check the X-distance, © Info I The piston should not raise the gauge off of the cylinder. jistance (distance from adjusting | 0... 0.10 mm (0... 0.0039 in) gauge to piston) » If the specified value is not reached: = Set the X-distance. (* p. 112) 15.5.23 Setting the X-distance © Info ‘The X-distance is adjusted by inserting cylinder base gaskets of various thicknesses. Preparatory work = Check the X-distance. (€ p. 112) = Remove the cylinder. ( p. 84) Main work = Replace cylinder base gasket @ by a cylinder base gasket of the appropriate size, Finishing work = Install the cylinder. (# p. 111)15 ENGINE 15.5.24 Adjusting the ignition Peston the piston at bottom deac center. Apply special toot @ tothe cylinder. 113 Adjustment gauge (46129006100) (* p. 154) Info T Apply the speciat tol with label ignition onto the cylinder. Turn the crankshaft counterclockwise until the upper edge of the piston rests against the special tool. Turn the stator ut markings @) ae aligned Tighten sorons @ Guideline Screw, ignition MS 5 Nm Loctite® 222 system/stator (3.7 Ibe fe Postion the alternator cover. Mount and tighten screns @. Guideline Screw, alternator cover Me 8 Nm (5.9 IID Lubricate the shaft seal ring prior to installation. Longzlife grease (* p. 152) Mount O-ring @.15 ENGINE na = Mount spacer @ with the chamfer facing inward 15.5.27 Installing the engine sprocket ~ Slide on the engine sprocket with the collar facing the engine. Mount lock ring @. 15.5.28 Installing the exhaust control valve Mount exhaust contol valve @ 15.5.29 Installing the cylinder head = Mount the cylinder head gasket. Info TH Ensure that dowel pin is seated correctly. Mount the cylinder head. Mount screws @ with the washers and tighten in a criss- cross patter, Guideline Screw, cylinder head 7 TsNm (23.3 bff © Info Always use new screws and washers.15 ENGINE 15 15.5.30 Installing the exhaust contro! ~ Mount both Ovings @ = Position spring @. = Postion the red valve housing ofthe exhaust cont = Mount and tighten screns @. Guideine Screw, reed valve housing of exhaust [ ME 5 Nev (3.7 IF) control = Mount and tighten screws @. Guideline Screw, reed valve housing of exhaust [ M6 10 Nin (7.4 TOF TD control = Position the diaphragm: = Mount aut @ but donot tighten yet ~ Pull up the diaphragm. Hold the shaft of exhaust control @. = Tighten nut @ Guideline ‘Nut, exhaust contral diaphragm ue 4 Nim (3 Toff) = Position the diaphragm cover ofthe exhaust contal = Mount and tighten screws @. Guideline Screw, diaphragm cover of exhaust | MS 4 Nm (3 Ib ft) control15 ENGINE 116 15.5.31 Installing the spark plug = Mount and tighten spark plug Guideline Spark plug MiOxt 10... 12 Nm (7.4... 8.9 tof 1 Spark plug wrench (60029073000) (* p. 158) 15.5.32 Installing the oil drain plug, Guideline = Mount and tighten the oil drain plug with magnet @ and the new seal ring, Oil drain plug with magnet Miz 5 20Nm (24.8 tof FY) f200746-10) 15.5.33 Installing the clutch pressure piece 15.5.34 Removing the engine from the universal mounting rack = Remove screw cap @. = Mount clutch pressure piece @ = Remove the engine from the universal mounting rack.16 CARBURETOR WW Preparatory work = Remove the seat. (** p. 53) Turn the knurled screw on the fuel tap all the way clockwise Dismount the fuel tank. (** p. 53) = Remove the main silencer. (7 p. 49) Main work = Unscrew hose clip @ = Loosen screw @. = Remove screw @ = Swing up the tai piece Info Tay attention to the carburetor connection boot. = unserew hose clip @. = Pull the carburetor out of the intake flange. = Remove screws ©. = Remove the tote side cover and pull the trate slide out ofthe carburetor. = Dain the remaining fel16 CARBURETOR = 300867-10 fi 30086610 > a 0086-11 = 300867-11 18 ~ Pull back the thotte slice spring and plastic lock @ ~ Detach throttle cable @. = Remove the throttle slide, Main work =" Attach thetle cable @. ~ Poston plastic lock @ = Position the trate slide spring. = Postion the throttle slide and trol slide cover. = Mount and tighten screns @. Guideline Screw, carburetor cover wa Shin G2 BFR) = Mount he carburetor = Position an tignten hose clamp @.16 CARBURETOR 19 = Position the tal piece. = Position the carburetor connection boot = Mount and tighten screns @. Guidetine Screw, tail piece ws 35.Nm Loctite? 243 (25.8 bt ft) ~ Tighten screws @, Guideline ‘Screw, tail piece Me 35.Nm Loctte® 243 (25.8 bt ft) = Tighten hose clip Finishing work = Install the main silencer. (* p. 49) = Install the fuel tank. (* p. 54) = Mount the seat. (* p. 53) = Check the play in the throttle cable. (** p. 29) = Carburetor - adjust the idle speed. ( p. 125) Condition The carburetor has been removed. ull the hoses off of the carburetor. = Remove screws @. = Remove the float chamber. ~ Remove seal.16 CARBURETOR 120 ~ Remove fulcrum pin @. ~ Remove teat @ and te fost needle valve. — Remove main jet @ with the washer. ~ Press needle jet @ cut ofthe carburetor inthe cretion of he venturi tube, = Remove screw @. = Remove the valve seat ofthe flat needle valve wth the lock washer. = Remove idling jet @. = Note the setting ofthe idle air acsting screw @. = Remove the idle ar adjusting screw. Info TH Make sure not to misplace the spring.16 CARBURETOR 121 ~ Bend open lock washer @. ~ Unscrew the choke slide. — Remove idle speed adjusting screw @ with the spring and O-ring. = Remove scens @ = Remove the jet neecle with the spring retainer, Position the choke slide with the choke lever. = Tighten the choke slide. Guideline Choke side Mio 5 Nm (3.7 Wot) Secure the choke slide with the lock washer. = Mount the speed adjusting screw with the spring and O-ring. ‘ternative 1 ~ Mount idle air adjusting screw @ with the spring. = Set the idle air adjusting screw to the specified value. Guideline Idle air adjusting screw Open 35 turns16 CARBURETOR 122 ‘Alternative 2 = Set the idle air adjusting screw to the value determined when it was disassern- bled. Mount and tighten idling jet @. Guideline Taling jet Max07 2 Nm (1.5 ITA = Poston the set ofthe float needle valve with the lock washer ~ Mount and tignten screw @. Guideline Other stews, carburetor we ZN SRR = Position needle jet @ in the carburetor. 7 The pin engages in the recess. = Mount and tighten main jet @) with the washer. Guideline Main jet 50.75 2Nm (1.5 TR) = Position the float needle valve and float @. = Mount fulerum pin @ = Checkiset the float level. ( p. 125) = Mount the gasket. = Position the float chamber. = Mount and tighten screns @. Guideline Other screws, carourator a 2m (LS BFR)16 CARBURETOR 123 = Mount the hoses on the carburetor. ~ Position the jt needle wit the spring retainer in the throttle slide, ~ Mount and tighten screws @. c @ 30088101 = Disassemble the carburetor. (Fp. 119) Check the jet needle, (* p. 124) = Check the throttle slide. (** p. 124) Check the float needle valve. (* p. 124) = Check the choke slide, (** p. 124) = Assemble the carburetor. ( p. 121)16 CARBURETOR 200877-10 300878-10 700057.101 00948-10 Condition The jet needle has been removed. ~ Check the jet needle for bending and wear of the coating. » If the jet needle is bent, or the coating is damaged or worn: = Change the jet needle. = Check the needle clip for tightness. » Ifthe needle clip is loose: = Change the needle clip or jet needle, Condition The throttle slide has been removed. ~ Check the throttle slide for damage and wear. » Ifthe throttle slide is damaged or worn: = Change the throttle slide. Condition The float needle valve is removed. = Check the float needle valve including the valve seat for deposits. >If there are deposits: = Clean or change the valve seat and float needle valve, Carburetor cleaner (* p. 152) — Check the float needle valve for wear and the sealing area for notches. » If the sealing area is damaged or worn: = Change the float needle valve. Condition ‘The choke slide has been removed, = Check the choke slide for smooth operation. » Ifthe choke slide is stiff and soiled: = Clean the choke slide and check its activation. Carburetor cleaner (* p. 182) = Check the piston of the choke slide for damage and wear. » If the piston of the choke slide is damaged or worn: = Change the choke slide. = Check the rubber sleeve and lock. » Ifthe rubber sleeve is damaged or brittle, or ifthe lock is not functioning: = Change the choke slide.16 CARBURETOR 125 Condition The carburetor and float chamber are removed. Tilt the carburetor sideways, preventing the fulerum pin from falling out. Tilt the carburetor until tne float is resting against the float needle valve, but the float needle valve is not being pressed together. » Ifthe edge of the float is not parallel (max. 1° deviation upwards) to the sealing area of the float housing in this position: ~ Adjust the flat level by bending toa ever @. ~ Screw in idle air adjusting screw @ all the way and turn it to the specified basic position Guideline Iie air adjusting screw Open 3.5 tums = Run the engine until warm. Guideline Warm-up time 25min Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness andior death. = When running the engine, always make sure there is sufficient ventila- tion, and do not start or run the engine in an enclosed space without an effective exhaust extraction system. = Adjust the idle speed with the adjusting screw @. Guideline (Choke function deactivated — The choke lever is pushed up all the way. Idle speed 1,400... 1,500 rpm ~ Turn idle air adjusting screw @® slowly in a clockwise direction until the idle speed begins to fall. = Note the position and turn the idle air adjusting screw slowly counterclockwise unt the idle speed falls again. Adjust to the point between these two positions with the highest idle speed. Info Tir tne engine speed rises considerably, reduce the idle speed to a normal level and repeat the above steps. It the procedure described here does not lead to satisfactory results, the ‘cause may be a wrongly dimensioned idling jet. If you can turn the idle air adjusting screw to the end without any change of engine speed, you need to install a smaller idling jet. After changing the idling jet, start from the beginning with the adjusting, steps. Following extreme air temperature or altitude changes, adjust the idle speed again.16 CARBURETOR 128 (16.12 Emptying the carburetor float chamber Danger Fire hazard Fuel is highly flammable, = Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fusl immediately. ~The fuel in the fuel tank expands when warm and may emerge if overflled. Follow the instructions on refueling. Warning Danger of poisoning Fuel is poisonous and a health hazard, Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact accurs with the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. If fuel is swallowed, contact a physician immediately. Change clothing that has been contaminated with fuel. Store fuel properly in a suitable canister and keep away from children. Warning Environmental hazard Improper handling of fuel is a danger to the environment. = Do not allow fuel to get into the ground water, the ground, or the sewage system. Info carry out this work with a cold engine. Water inthe float chamber results in malfunctioning. Preparatory work = Turn the knurled screw on the fuel tap all the way clockwise. 7 Norere tue! tows fom the tnkt the carburetor Main work pace a cloth beneath the crburtorto soak up emerging fel = Remove pug @. = Completely dain he tel Mount an tighten the plus.17. CLUTCH 127 171 Checking the fuid level of the hydraulic clutoh © Info The ttuid level rises with increasing wear of the clutch facing discs. = Move the clutch fluid reservoir mounted on the handlebar toa horizontal positon = Check the fluid level in viewer @. Ifthe fluid has dropped below marking @ in the level viewer: = Correct the fluid level ofthe hydraulic clutch Environmental hazard Hazardous substances cause environmental damage, = Oil, grease, filters, fuel, cleaners, brake fluid, etc, should be disposed of as stipulated in applicable regulations. © Info ‘The fluid level rises with increasing wear of the clutch facing discs. = Move the clutch fluid reservoir mounted on the hanclebar to a horizontal positon = Remove screws @. ~ Remove cover @ with membrane ©. = Fill Bleeding syringe @ withthe appropriate hydraulic fluid. Bleed syringe (50829050000) (* p. 157) Brake fluid DOT 4 / DOT 5.1 (© p. 150) = Onthe slave cyinger, remove the bleeder screw and mount bleeding syringe @. = Inject te quid int the sytem uni it escapes from dil note @ of the master cylinder without bubbles, = To prevent overlow, cain fluid occasionally from the master cylinder reservoir. = Remove the bieeding syringe. Mount and tighten srews bleeder sre = Correct the Hui level ofthe hydraulic clutch Guideline Fluid level below container rim mm (0.16 i — Position the cover with the membrane. Mount and tighten the screws.