15 ENGINE Preparatory work = "Raise the motoreyle withthe lit stand. (=p, 9) ~ Remove the seat. (2p. 59) ~ Turn tap handle @ on the uel tap tothe OFF poston (Figure C00462-10""p. 59) = Remove the fuel tank. (=p. 60) = Drain the coolant. (5 p. 145) = Remove the manifold. ( p. 54) Main work = Loosen hose clip @. ~ Remove sereus @ = Loosen serews @ = Swing up the subframe and secure it. = Loosen hose tip @. = Pull the carburetor earward out ofthe intake flange and hang it to one side ~ Pall off vent nose @ = Pullotf spar pug connector @15 ENGINE Loosen nose clip @. Take of the radiator hose. Loosen hose clip @. Take off the radiator hose. Disconnect spring @. Remove screw ® Remove screw @ with the sleeve Take ofthe engine sprocket cover Remove the connecting link of the chain. Take off the chain. Remove screws @. Take off the clutch slave cylinder and hang i to the side Info Do nat kink the clutch line. Do nat pull the clutch lever while the clutch slave cylinder is removed,15 ENGINE 86 ~ Disconnect connector @ = Remove the cable binders and expose the cables. = Remove screw connections @®. = Remove the engine braces. = Remove screw @ with the washers. — Take ff the shift ever = Remove nut ® = Remove the swingarm pivot. = Pal the swingarm slightly toward the rer. = Remove screws @. = Lift out the engine from the side. © Info ‘You should have an assistant for this step. Make sure that the motorcycle is sufficiently secured against falling over. Protect the frame and attachments from damage.15 ENGINE 87 Main work = Position the engine in the frame. Info TThe hetp of an assistant is useful in this step. Make sure that the engine is sufficiently secured against falling over. Protect the frame and attachments against damage = Mount screws @ but do not tighten yet. Guidetine Engine canying sew Mio a5 Nim (33.2 bof = Position the swingarm. = Mount the swingarm pivot. = Mount nut @, but do not tighten it yet. Guidetine ‘Nat, swingarm pivot Mia 75m (55.3 Io f — Position the engine braces. = Mount and tighten fittings @. Guideline Screw, engine brace ua Nim (24.3 tor fo = Tighten screws @ and nut @. Guideline Engine canying screw Mi0 a5Nm (33.2 bof) Nut swingarm pivet Mia 75m (55.3 bof) = Position the shift lever = Mount and tighten screw @ withthe washers. Guidetine Serew, shift lever we T2Nm Toate 203 (91m15 ENGINE ~ Plugin connector © = Route the cable and secure witha cable tit). = Position the clutch slave cylinder with the O-ring Mount and tighten screws @. 88 Guideline ‘Screw, slave cylinder of | M6 10Nm octite® 243 the clutch (7.A tof = Mount the chain ~ Connect the chain wth connecting link @. Guideline The closed side ofthe chain jin Tock mut face in the diction of rave = Position the engine sprocket cover ~ Mount an tignten screw @ with he bushing Guidetine Screw, slave cylinder of | M6 10Nm Loctite® 243 the clutch (7a tbr ft) ~ Mount and tighten screw @. Guideline ‘Screw, engine sprocket | MB 15.Nm Loctite® 243 cover (21.1 Ib ft) Attach spring @. Mount the radiator hose, ~ Position an tighten hose clip @.15 ENGINE 89 = Mount the radiator hse = Position an tigen bose clip @. ~ Mount spark plug connector @®. = Slide the carburetor into the intake flange. Position and tighten hose clip ©. = Mount vent hose @®. = Remove the lacking piece and position the subframe, Info Watch out for the intake flange. = Mount and tighten screw @ Guidetine Screw, subframe MB 30 Nm (22.1 bor = Remove screws @. = Mount and tighten screws @®. Guideline Screw, subframe wa 30 Nm (22.1 bof) Position and tighten hose clip @. = Install the manifold. (© p. 54) = Install the fuel tank. (© p. 60) = Mount the seat. (= p. 59)15 ENGINE 15.3 15.3.1 Engine disassembly = Remove filer plug @ ane fll up with gear oi Gear oll (0.50 1(0.53 gt) _| Engine oll (15W/50) ( p. 168) — Mount and tighten ot filer plug @ with the o-ring Finishing work = Remove the motorcycle from the lft stand. (® p. 9) Refill the coolant. ( p. 145) Take a short test ride. Check the cooling system for leaks. Check the engine for leak tightness. Check the gear oil level. (5 p. 148) Check the coolant level, (52 p. 147) Clamping the engine into the engine assembly stand 15.3.2 20612810 ‘Removing the engine sprocket = Mount special too! @ on engine assembly stand @ Engine assembly stand (61223001000) (™ p. 176) Holder for engine assembly stand (46229001070) (= p. 172) = Install the engine, Fifting for engine assembly stand (46229001060) (= p. 172) = Remove lock ing @ — Take off engine sprocket @. ~ Remove clutch pushrod @) and the bl15 ENGINE 15.3.4 Draining the gear oil 15.3.5 Removing the spark plug 15.3.6 15.3.7 a1 = Remove the oil drain plug @ with the magnet and seal ring. ~ Completely drain the gear oll = Remove spark plug @. ~ Alternately loosen screws @) and remove them. ~ Remove the cylinder head. — Remove cylinder head gaskets @ and © ~ Remove screws @ = Remove the alternator cover.15 ENGINE 15.3.8 Removing the kick starter 15.3.9 Removing the exhaust control — Remove screw @ with the washer. = Remove the kick starter. = Remove screws @ = Remove cover Q. ~ Remove tall socket @. = Take off gasket ~ Remove nuts @ on both sides. = Caretully side the cylinder up and take i of = Remove cylinder base gasket @ 9215 ENGINE 3 15.3.11 Removing the piston = Cover the engine case opening with a cloth. = Remove the piston pin retainer @. = Remove piston pin. Toke off the piston, ~ Remove the upper conrod bearing @ ~ Hola the rotor using special oo! @. Holding spanner (64629012200) ( p. 178) ~ Remove nut @ withthe washer. = Mount special too! @. Protecting sleeve (26229090000) (= p. 173) = Mount special too! @, apply counterpressure, and pul off the rotor by screwing in the sce Extractor (64629009044) (™ p. 178) ~ Remove cabe sleeve @ out ofthe engine case. ~ Remove screus @ = Remove the stator.15 ENGINE 15.3.14 Removing the spacer ~ Remove spacer @ of the countershatt = Remove Oving @. ~ Remove scews @. Takeoff the clutch cover. Info Ensure that the kick starter shaft remains in the engine case. = Remove the dowels and clutch cover gasket. ~ Loosen screws @ and remove together withthe washers and springs. = Remove pressure cap @ ~ Toke off pressure piece @ with the axial bearing Info The washer @ ote axial bearing may adhere tothe pressure cap15 ENGINE 95 = Fully remove clutch pack @. ~ Bend up the lock washer. = Hold the inner clutch hub with the special too. Clutch holder (47029003000) (== p. 173) ~ Remove nut @ with the lock washer. ~ Takeoff inner clutch hub @ and washer @ Info The washer usually sticks to the inner clutch hub. = Take off clutch basket @. ~ Toke oft needle bearings @. ~ Remove bushing @ and stop cisk @. = Hola the primary gear using special too! @. Clutch holder (47029003000) (= p. 173) = Remove screw @ = Take off the primary gear.15 ENGINE ~ Remove woodrutt key @. — Remove distance sleeve @ = Remove O-ring = Hold kick starter spring @. = Remove screw @ with the bushing = _Slacken the hick starter spring, = Remove kick starter shaft @ with the washer © Info Turn the kick starter shat slighty to the left The washer usually sticks to the bearing. 15.3.19 Removing the intermediate kick starter gear Remove lock ing @ ~ Take ft intermediate kik starter gear @) with the washer. Remove washer @ Push sliding plate @ away from the sit dum locating unit @ = Remove shift shat © withthe washer.15 ENGINE 7 15.3.21 Removing the shift drum locating unit = Remove screw @. Push away locking lever @ from shift drum locating unit @ and remove the shift drum locating unit = Relieve tension from the locking lever. = Remove screw @ ~ Take off locking lever @, washer, sleeve, and spring. 15.3.23 Removing the reed valve housing = Remove screws @. = Take off the intake flange. f206205-10, = Remove teed vahe housing @. = Toke off he gasket, 15.3.24 Removing the left engine case section ~ Remove screws @ ~ Till the let section of the engine case upward and remove the screw connections of the engine fixing arm. ~ Take off the left section of the engine case.15 ENGINE 98 — Remove engine case gasket @. 0622510, 15.3.25 Removing the shift rails ~ Remove shift rails @ with the springs. ~ Tit shit rks @ to the sce © Info o nat misplace the shift rollers. = Remove sit um @ ~ Remove shit forks @ i= Do not misplace shift rollers @ ~ Pull both transmission shats @ out ofthe besring seats together. © Info The stop disks of the transmission shatts usually stick to the bearings.15 ENGINE 15.3.29 Removing the crankshaft Remove crankshett @. Info Tirnecessary, strike the crankshaft journal lightly with aplastic hammer. 15.4.1 Working on the right section of the engine case oe Remove the dowels Remove erankshatt seal ing @). ‘Warm the engine case section in an oven Guideline 1506 G02 7) Kock the engine case section against a level wooden plate, Ths will cause the bearings to dropout of the bearing seat. Info TL Any bearings that remain in the engine case section must be removed using 2 suitable tool Insert the new cold bearings in the bearing seats of the heated section of the engine case; if necessary, use a suitable press drift to push them from the inside to the outside to the stop or until they ae flush © Info I When pressing the bearing in, ensure that the engine case section is level to prevent damage. Only press the bearings in via the outer bearing race; otherwise, the bear- ings will be damaged when they are pressed in. After the engine case section has cooled, check that the bearings are firmly seated. © Info Tit the bearings are not firmly seated after cooling, itis tkely that they wll rotate inthe engine case when warm, In tis case, the engine case must be renewed. Press crankshaft seal ring @) tom the outside tothe inside withthe open sie fac. ing inward Info T The shatt seat ring must be flush on the outside.15 ENGINE 100 15.4.2 Work on the left section of the engine case f06257-10, Remove the dowels. Remove crankshatt seal ring @). Remove shaft seal ring @ of the countershatt. Remove shat sal ring @ ofthe shift shat. Warm the engine case section in an oven Guideline 150° (3027) Knock the engine case section against a level wooden plate. This wil cause the bearings to drop out of the bearing seats. Info. TL Any bearings that remain in the engine case section must be removed using a suitable tool. Insert the new cold bearings in the bearing seats of the heated section of the engine case; if necessary, use a suitable press drift to push them from the inside to the outside until they are flush. Info T When pressing the bearing in, ensure that the engine case section is level to prevent damage. Only press the bearings in via the outer bearing race; otherwise, the bear ings will be damaged when they are pressed in. After the engine case section has cooled, check that the bearings are firmly seated. Info Tir the bearings are not firmly seated after cooling, itis likely that they will rotate in the engine case when warm. In this case, the engine case must be renewed Press crankshaft seal ring @ from the outside to the inside with the open side fac- ing inward ress shatt seal ing @ of the countershat from the outside tothe inside withthe ‘open side facing inward Info H_The shatt seal rings must be flush on the outside. ress shat eal ing @ ofthe sift shaft from the outside tothe inside withthe open sie facing iar uni is fash, Blow out oil channel @ with compressed air and check that it is clear.15 ENGINE 15.4.3 Removing the crankshaft bearing inner 101 Sf race ~ Firat te crankshat in the vice with special tol [20628810 Warm up special too! @. Guideline Press plate (46229047050) ( p.173) Info Use soft jaws. 150°C (302 °F) Tool for inner bearing race (58429037031) ( p..175) 15.4.4 Installing the crankshaft bearing inner rush tne warmed up spacial tol @) onto the eankshat bearing nner race, press firmly together and pull only from the crankshaft. F race Fivate the crankshaft in the vice with special tool @. Press plate (46229047050) (" p. 173) 2 Info Use soft jaws. Heat the crankshaft bearing inner race in special tool @ and mount together. Guideline [206289-10, 15.4.5 Changing the connecting rod, conrod Mai 120°C (248 *F) Tool for inner bearing race (58429037031) (= p. 175) Ensure that the new crankshaft bearing inner race is flush. bearing, and crank pin in work Position special tool @ between the crankwebs. Press plate (46229047050) (= p. 173) Position crankshaft in the press using special tool. Press the crank pin out of the upper crankweb with a suitable push-out drift, © Info Hold the lower crankweb. Remove the connecting rod, bearing, and stop disks. Press the crank pin out of the crankweb.15 ENGINE Position the crankweb with the spec 102 jal tool, ‘Anchor plate (46229047002) ( p.173) ~ Press in the new crank pin @ as fr a8 possible. 306294-10 = Mount stop disks @, bearing, and connecting rod @. Info Thoroughly oil the bearing. 30628610 ~ Postion special tool @ onthe press, Pressing device, crankshaft, complete (50329047000) ( p. 174) Press plate (46229047050) ("= p. 173) KW pressing tool (47029008000) (p17) = Insert the erankweb with connecting, ~ Position the second crankweb. ~ Position special too! @ withthe heel pointing down, [ Gover. crankshaft pressing device (46229008002) ( rod and bearing. p.173) © Info 5 possible. Press in the upper crankweb as far a TThe press mandrel must be positioned over the crank pin, = Take the crankshaft out of the special tool and check that the connecting rod can move freely ~ Measure axial play @ between the stop disk and the crankwebs using the special tool [Feeler gauge (59029041100) (= p.176) p. 176) 306264-10 Connecting rod - axial play of lower conrod bearing 0.40... 0.60 mm (0.0157. 0.0236 in) » Ifthe specification is not reached: = Correct the axial play to the specified value. ishing work = Check the crankshaft run-out at the bearing pin. (22 p, 103)15 ENGINE 103 15.4.6 Checking the crankshaft run-out at the bearing pin 15.4.7 Checking/measuring the cylinder 0623610, 30623710) 15.4.8 Removing the exhaust control 206261-10, Position the crankshaft on a centering block. Turn the crankshaft slowly. Check the crankshaft run-out on both bearing pins. $0.03 mm (0.0012 in) Crankshaft - run-out at bearing pin » If the crankshaft run-out at the bearing pin is larger than the specification: Align the crankshaft. Check the cylinder bearing surface for damage, If the cylinder bearing surface is damaged Change the cylinder and piston. ‘Measure the cylinder diameter at several locations on the @9- and @-aves using a ‘micrometer to identify oval wear. Guidetine Cylinder - drill hole diameter ‘Size A 47.025... 47.037 mm (1.85137... 1.85185 in) Size B 47.037... 47,050 mm (1.85185... 1.85236 in) Info T the eytincer size @ is marked on the side of the cylinder. Using a straight edge and the special tool, check the sealing surface of the cylinder head for distortion Feeler gauge (59029041100) ( p. 176) Cylinderieylinder head - distortion of | = 0.10 mm (= 0.0039 in) sealing surface » Ifthe measured value does not equal the specified value: Change the cylinder Remove screw @ with the bushing and spring. Take off adjusting lever @.15 ENGINE 30626210 104 = Remove serous © ~ Toke off stp pate @. Remove drive plate @. = Remove sceus © = Take of the exhaust flange. = Remove screw @. = Remove closure cap @. — Take off the control flap. = Remove beerng sleeves @.15 ENGINE 15.4.9 Checking the exhaust contro! 306268.10] ~ Chock bearing stooves @ for damage and wear. >I there is damage or wear: = Change the bearing sleeves. = Check control flap @ for damage and wear. > Hf there is damage or wea: = Change the contol fap = Check spring @) for damage and wear >It there is damage or wea: ~ Change the spring 154.10 Installing the exhaust control 206267-11 306266-11 Main work Clean all parts well Info T contamination of the control flap can lead to blockages. ‘Mount and grease he O-rings. 105 Long-ife grease (© p. 170) Mount bearing sleeves @ onto the conto lap withthe clit facing outward Position the preassembled conta flap inthe cylinder Mount elosure cap @ with the Oring.15 ENGINE a 0 EO 2 i a 108 Mount and tighten scren @ Guideline Lack screw for control flap | M6 @Nm Toatite® 243 (5.9 Ib fo) Degrease the sealing surface and thinly coat it with sealant. Loctite? 5910 ‘Mount the exhaust flange. ‘Mount and tighten screws @. Guideline Screw, exhaust flange | M6 1ONm Toctite® 243 (7.4 tof fo Check the exhaust control for smooth operation Mount river plate @ Position stop plate @ withthe stop facing inward Mount screw @ but donot tighten ve. Guideline Seren, stop plate of exhaust contol [MB Em (a BI Position stop lever @. Position the spring with the short leg facing outward. ‘Mount screw @ with the bushing and spring but do not tighten yet. Attach the spring to the cylinder pin. ishing work Adjust the Z-distance, (" p. 130)15 ENGINE 15.4.1 Checking/measuring the piston 30624810 30624910, 107 Check the piston bearing surface for damage. » If the piston bearing surface is damaged: = Replace the piston and, if necessary, the cylinder. CCheck that the piston ring moves easily in the piston ring grooves. » Ifthe piston ring i sift = Clean the piston ring groove. ip TAnotd piston ring can be used to clean the piston ring groove Check that the piston ring for damage. > Ifthe piston ring is damaged: = Change the piston ring, Info TH ount the piston ring with the marking facing upward. CCheck the piston pins for discoloration or signs of wear. » Ifthe piston pin shows severe discolorationsigns of wear: = Change the piston pin. Place the piston pin in the connecting rod and check the seating for play. » Ifthe piston pin seating has excessive play: = Change the connecting rod and piston pin. Check the piston ring anti-rotation lock for damage and tightness of fit, » Ifthe piston ring anti-rotation lock is damaged or loose: = Change the piston, Check the piston pin bearing for damage and wear. >If there is damage or wear: = Change the piston pin bearing or connecting rod. ‘Measure the piston at the piston skirt, at right angles to the piston pin, at a distance ®. Guideline Distance @ Piston - diameter ‘Size 1 50 mm (1.97 in) 46,955... 46.965 mm (1.84862... 1.84901 in) 46.965... 46.975 mm (1.84901... 1,84941 in) ‘Size 2 15.4.12 Checking the piston ring end gap g 30623810 © Info T Piston dimensions @ are marked on the piston head. Remove the piston ring from the piston Pace the piston ring in the cylinder and align with the piston. Guideline Below the upper edge of the cylinder 10 mm (0.39 in) Measure end gap @ with a feeler gauge. Guideline Piston ring - end gap 5 0,60 mm (5 0.0236 in) » Ifthe end gap is greater than the specified value: = Checkimeasure the cylinder. (° p. 103)15 ENGINE 108 » I eylinder wear lies within the specified tolerance: = Change the piston ring, 15.4.13 Pistowoylinder - measuring the mounting clearance diameter. Guideline = Check/measure the cylinder. (© p. 103) = Measure the piston/cylinder mounting clearance. (* p. 108) = The smallest piston/cylinder mounting clearance equals the smallest cylinder bore diameter minus the largest piston diameter. The largest piston/cylinder mount: ing clearance equals the largest cylinder bore diameter minus the smallest piston Pistonicylinder - mounting clearance 30624810, New condition 0.060... 0.085 mm (0.00236... 0.00336 in) Wear limit {0.10 mm (0.0039 in) 154.14 Checking the reed valve housing, reed valve, and intake flange > If there is damage or wear: = Change the reed valve housing » If there is damage or wear: = Change the reed valve. weasel » lf there is damage or wear: = Change the intake flange. 154.15 Work on the clutch cover = Remove screws @. = Remove the closure cap. = Remove scens @ = Take of the water pump cover. ~ Remove cover @ 306271-10. ~ Check the reed valve for damage and wear. = Check reed valve housing @ for damage and wear. = Check intake ange @ for damage and weer.15 ENGINE 109 — Remove stud @ with te washer. ~ Pull sealing element @ out of the clutch cover. ~ Remove adjustment cable @ with the linkage. 306273510, Hola the centrifugal timer with a suitable too. = Remove nut @ ~ Remove centrifugal timer @. ~ Hola the water pump drive gear with a suitable too. = Remove screw @ and takeoff the water pump impel. = Remove water pump erve @®. = Take off washer @.15 ENGINE 110 ~ Remove shat sel ring ®. Remove shaft seal ring ®. = Warm the cluten cover in an oven, Guidetine 150°C (302 *F) ~ Knock the clutch cover against a level wooden plate. This will cause the bearings to drop out of the bearing seat. Info HThe bearings that remain in the clutch cover must be pressed out with a suitable toc. = Insert the new cold bearings in the bearing seats of the heated clutch cover: if nec- ‘essary, use @ suitable press drift to push them all the way in and make them flush. Info T when pressing the bearing in, ensure that the clutch cover is level to pre- vent damage. Only press the bearings in via the outer bearing race; otherwise, the bear- ings will be damaged when they are pressed i — After the clutch cover has cooled, check that the bearings are firmly seated. Info Tir the bearings are not firmly seated after cooling, iti likely that they will folate in the clutch cover when warm, In this case, the clutch cover must be renewed,15 ENGINE <9 ae © Po ° @ s06281.10 ~ Check pins €B ofthe conta lever for damage and wear. > there is damage or wear: = Change the control lever ~ Check ball heads €B of the linkage for damage and wear. >If here i damage or wea: = Change the inkage. ~ check cenitugal timer @ for damage an wear > Hf there i damage or wear: — Change the centitugl timer, ~ check water pump drive @ tor damage and wear > thee is damage or wear: = Change the water pump civ, ~ Press in shat sel rng @ until itis sh, mt = Press shaft seal ring @ from the outside to the inside with the open side facing Inward until itis flush,15 ENGINE a 30627310. Mount washer @. Position water pump drive @. Mount water pup impeller. Hold the water pump drive gear with a suitable tok Mount and tighten screw @. Guideline Mount centiuga timer @. Hold the centifugl timer with suitable too Mount and tighten nut @ 112 Guideline ‘Nat, centrifugal timer | M6 10 Nm Lootite® 243™ (7.4 tof Mount adjustment cable ® with the linkage. Mount and tighten stud @ with the washer. Guideline ‘Stop screw for adjustment | Ma aNm Lootite® 243 cable Bibi Position sealing element @ in the clutch cover.15 ENGINE Ey 30627110. mount cover @ Mount the gasket and position the water pump cover. ‘Mount and tighten screws @. Guideline 113 Mount the gasket and positon the closure cap, Mount and tighten screns @. Guideline Screw, water pump cover Me TO Nm (7.4 IBF) Locking cap screw MS 8 Nm (5.9 Ibi A) 306240: ~ Check pressure piece @ for damage and wear. > If there is damage or wear: = Change the clutch throw-out. = Cheok the length of clutch springs @. Clutch spring - length 2 33 mm (2 1.3 in) >If the clutch spring length is shorter than specified:15 ENGINE = Change all clutch springs. ~ Check the contact surface of inner clutch hub @ for damage and wea. + If there is damage or wea: = Change the inner clutch hub = Check the thrust surfaces of the clutch facing dics in clutch basket @ for wear. 4 Contact surface of clutch facing dises in clutch basket 50.5 mm (= 0.02 in) > Hf the thrust surface exhibits excessive wea: = Change the clutch facing discs and the clutch basket. ~ Check needle bearings @ and bushing @ for damage and wear, > Hf there is damage or wea: = Change the needle bearings and bushing. = Check intermediate clutch dises @ for damage and wear, Hi the intermediate clutch dises are not level and are pied = Change all intermediate elute cscs ~ Check clutch facing dises @ for discoloration and scoring It there ie discoloration or scoring = Change al luton facing diss. ~ Check the thickness of clutch facing cises © Clutch facing disc - thickness 2.8 mm (20.11 in) > IV the eluteh facing dle doesnot meet specifications = Change all luton facing discs. ~ check elute pressure cap @ for damage and wes > thee is damage or wear = Change the clutch pressure cap 15.4.17 Checking the shift mechanism os oy POR? Bo @ . ye o wt ¢ >. = Check shift forks @ on disc @ fox damage and wear (visual checla >t there is damage or wer: = Change the shift for and gear wheel pal. ~ Check sit grooves @ of sit drum @ for wear. > Ifthe sit groove is wen = Change the sit eum, ~ Check the seating ofthe sit drum in bearings @ «, 306241-10]15 ENGINE 115 >If the shit drum isnot corectly seated = Change the shitt drum andor bearings. ~ Check bearings @ for smooth operation and weer. > Ifthe bearings ae tif r wen = Change the bearings. = Check the shift rollers for damage and wear. > Hi there is damage or wear = Change the shit rollers. ~ Check the springs ofthe shift rails @ for damage and wear. > Hf the spring is damaged or worn = Change the spring of the shitt als = Check shift ails @ for run-out ona flat surface. > 1 there i un-ou = Change the shit ails = Check shit ats @ for scoring, wear, and smeoth operation in the sift forks. >If scoring or wear is present or ofthe shift fork is ti = Change the shift rails. ~ Check ling plate @ for wear on contact areas @. > Hf the slicing plate is wor: = Change the slicing plate. ~ Check retun surface @ on te sling plate for wear > Ht there is severe grooving = Change the sliding pate ~ Check guide pins @ tor tightnes of it and wear. > Hf the guide pins are lose or worn = Change the sling plate. = Pressomble the shisha (2p. 115) = Check clearance @ between the sliding plate and the shift quadrant. | Shi shaft sing aH une [OA0.. 0.80 mm (O.OTS7-~ eo rant play 0.0315 in) 30624210 Secure the short end of the shift shaft in the bench vise. Guideline Use soft jaws. ~ Mount pressure spring @. = Slide on spring guide @, push return spring @, with the offset end facing upward, over the spring guide and lift the offset end over abutment bolt @. ~ Mount washer @. socase0] Mount lock rng @ = Mount stop disk @.15 ENGINE 116 15.4.19 Disassembling the main shaft we a4 206; 306243.10] ‘Secure the main shaft with the toothed end facing downward in the vise Guideline Use soft jaws. ~ Remove stop disk @ and second-gear fixed gear @. Remove sixth-gear idler gear @. ~ Remove needle bearing @ and stop disk @. ~ Remove lock ring @ — Remove third/fourth-gear sliding gear @ ~ Remove lock ring © = Remove fith-gear idler gear @. 15.4,20 Disassembling the countershaft 306245-10] = Fix the countershaft in the vice with the toothed end facing downward Guideline Use soft jaws15 ENGINE ~ Remove stop disk @ and firstgear iar gear @ — Remove needle bearing @ and stop disk @. ~ Remove fifth-gear sliding gear @. = Remove lock ring @. = Remove stop disk @. ~ Remove fourth-gear idler gear @ and needle bearing @. ~ Remove third-gear idler gear @. ~ Remove needle bearing @. ~ Remove stop disk ® and lock ring @. = Remove sinth-gear siding gear ©. = Remove lock ring @. = Remove stop disk @. = Remove second-gear idler gear @ and needle bearing @. 154.21 Checking the transmission Condition ‘The transmission has been disassembled, o = Check needle bearings @ for damage and wear > Ht there is damage or wea: = Change the needle bearing ~ Check the pivt points of main shaft @ and countershatt @) for damage and wear. > Hi there is damage or wear: = Change the main shaft and/or countershat ~ Check te tooth profiles of main shatt @ and counteshatt @) for damage and wear. > If there is damage or wea: = Change the main shaft and/or countershat = Check the pivot points of idler gears @ for damage and wear. > Hi there is damage or wea: = Change the gear wheel pai ~ Check the shtt dogs of idler gears @ and siding gears @ for damage and wear. > Hf there is damage or wear: — Change the gear whee par 715 ENGINE ~ check the tooth faces of ier gears @, sliding gears @, and fixed gear @ for damage and wear » there is damage or wear: = Change the gear wheel pair = Check the tooth profiles of siding gears @ for damage and wear. >I there is damage or wear: = Change the gear whee pair, ~ Check sliding gears @ for smooth operation inthe profile of main shaft @ >the sliding gear is tit: = Change the sliding gear or main shaft, ~ Check sling gears @ for smooth operation inthe profile of countershatt @. >the sliding gear is stifs = Change the siding gear or countershatt. ~ Check stop disks @ for damage and wear > there is damage or wear — Change the stop diss. = Use new lok rings @ with every repair 15.4.22 Assembling the main shaft 18 © Info Tse new lock rings with every repair. Preparatory work = Carefully lubricate all parts before assembling. Check the transmission. (®! p. 117) oe on s06244.10 work = Secure the main shaft with the toothed end facing downward in the vice Guideline Use soft jaws ~ Mount it-gear idler gear @ with the shit dogs facing up. = Mount ick ring @. ~ Attach thia/fourth-gear slicing gear @ withthe small gear wheel facing up and mount lock ring @. ~ Mount top disk @ and needle becring @. = Mount sixth-gear idler gear @) with the shitt dogs facing downward15 ENGINE 19 ~ Mount second-gear fixed gear @ and stop disk ©. ~ Finally, check all gear wheels for smooth operation 154.23 Assembling the countershaft © Info Use new lock rings with every repair. Proparatory work = Check the transmission. (®* p. 117) = Carefully lubricate all parts before assembling 306246-10 0° =. Fix the countershaft in the vice with the toothed end facing downward. Guideline Use soft jaws = Mount needle bearing @ and second-gear ialer gear @) onto the countershaft with the protruding collar facing downward = Mount stop disk @ ara lock ring @. ~ Mount sixth-gear sliding gear @ withthe shift groove facing up = Mount lock ring @ and stop cisk @. = Mount needle bearing @ and tir gear alr gear @ ~ Mount needle bearing @. = Mount fourth-gear idler gear @. ~ Mount stop disk €® anc lock rine @ ~ Mount fifth-gear sliding ear @ with the shitt grove facing downward — Mount stop disk @. ~ Mount needle bearing €B and fist. gear idler gear ~ Mount stop disk @. = Finally, check all wear whee!s for smooth operation15 ENGINE 154.24 Checking the kick starter 306250:10 ~ Check the gear mesh and bearing of kick starter gear @) for damage and wear. > Hi there is demege or wear Change the kick starter gear ~ Check the gear mesh and bearing of intermediate kick starter gear @) for damage and wear >Hi there is damage or wea: Change the intermediate kick starter gear = Check the gear mesh and contact surface of kick starter ratchet wheel @ for damage and wear, >It there is damage or wea: = Change the kick starter ratchet whee! ~ Check the gear mesh and bearing of kick starter shatt @ for damage and wear. » there is damage or wea: = Change the kick starter shat 154.25 Preassembling the kick starter shaft Mount lock ring @ and washer @. 306251-10. Y The catch @ is offset tothe lett of hole @. 30625410 = Mount kick starter ratchet whee! @ with the ratchet wheel spring, 12015 ENGINE 30625210, 30625510, oe B & 12 — Mount kick starter gear @ = Position spring @ and attach it to hole @. = Mount driving hub @. The recess is located above the end ofthe spring @. 50625310 15.5.1 Installing the crankshaft ~ Position te right section of the engine case inthe engine assembly stand ‘ Engine assembly stand (61229001000) (= p. 176) o Holder for engine assembly stand (46229001070) (= p. 172) = Warm up the erankshaft bearing Guideline 60°C (1407) ~ Slide crankshatt @ all the way into the bearing seat of the right section ofthe 06220510] engine case = Mount the dowels. 15.5.2 Installing the transmission shafts = Oilall bearing. Engine oll (15W/50) (= p. 168) = Assemble the two transmission shafts @ and slide them into the bearing seats together.15 ENGINE 15.5.3 _ Installing the shift forks 30 oe 286 0 15.5.4 Installing the shift drum 206635-10, 15.5.5 Installing the shift rails 122 Mount shift fork @ in the shift groove of the main shatt Mount shift fork @ in the lower shitt groove ofthe countershatt. — Mount sit fork @ inthe upper shift groove ofthe countershatt, ~ Position washer @) on te shift rum and fix with @ small amount of grease Slide shift drum @ wit the washer into the bearing seat Pt shit forks @ in the shift rum, © Info Do not misplace the shift rollers. Install sit als @ together with the upper anc lower spans. Tip TL Fix the springs in the shift rails with grease15 155.6 ENGINE 123 Installing the left engine case section af & 30663710 15.5.7 Installing the reed valve housing f306206-11 Clan the sealing surfaces. Mount engine case gasket @ Check that dowels @ are seated correct Mount washer @ and fix with a small amount of grease. ‘Mount the left section of the engine case. If necessary, strike lightly with a rubber mallet. © Info Do not use the screws to pull the two sections of the engine case together. Mount screws @ but donot tighten yet. Guideline Soren, engine case 6x8 TONm 7a wr TD Mount screws @ and tighten al screws ina crisscross pattern Guideline Seren, engine case WE TONm (a FAY ‘Secure the engine in the engine assembly stand. Remove the excess lengths of the engine case gasket in the area of the cylinder support and the reed valve housing, Position the gasket. Position reed valve housing @) in the engine case opening. Position the intake flange. ‘Mount and tighten screws @. Guidetine Screw, intake flangelreed valve housing | M6 10 Nm (7.4 bt FO)15 ENGINE 128 15.5.8 Installing the locking lever 7 ~ Mount locking lever @ withthe washer, sleve, and sping = Mount ang tighten sew @ Guideline Screw, locking lever | WB Té Nim ibe Ft) 15.5.9 Installing the shift drum locating unit = Press locking lever @ to the right and position the shift drum locating unit. % Pin @ engages in hole @. = Relieve tension frm the locking lve. = Mount and tighten screw @ Guideline ‘Screw, shift drum locating | M6 10Nm Loctite® 243 (7.4 Ibe ft ~ Slide sit shett @ with the washer into the beerng seat. = Push sliding plate @® away from the shift drum locating unit @. Insert the shift shaft all the way. = Let the sliding plate engage in the shift drum locating unit. = Shift through the transmission. 15.5.11 Installing the intermediate kick starter ge: = Mount washer @.15 ENGINE 15.5.12 Installing the kick starter shaft ras on a zi 15.5.13 Installing the primary gear ~ Position intermeciate kick starter gear @ with the washer Meunt locking @ Preassemble the kick starter shaft. (-* p. 120) Mount the preassembled kick starter shatt @ withthe washer Locking spring @ engages in recess @. 125 ‘ The catch @ of the kick starter ratchet wheel must be in contact with stop ©. Position kick starter spring @. Mount and tighten screw @ withthe bushing Guideline ‘Screw, kick starter Me 10 Nm (7.4 Io #0 Loctite® 243 Position the Oring, Mount distance sleeve @. Nount woodrut key @ Position the primary gear. Hold the primary gear using special tool @. Clutch holder (47029003000) ("= p. 173) ‘Mount and tighten screw @. Guideline Mi0xi.25 [80 Nm (59 Ibt ft) Primary gear screw Loctite® 24315 ENGINE 15.5.14 Installing the clutch discs 306195:10 Mou! Mount needle bearings @. stop disk @ and bushing @ 128 Slide the clutch basket onto the gearbox main shaft. Turn intermediate kick starter gear @ until the gear teeth of the clutch basket engage. ‘Mount washer @ and inner clutch hub @. Fesiton the new lock washer and mount nut @. Tighten the nut holding the ianer clutch hub with 2 special tool Guideline ‘Nat, inner eluteh hub Mi4x1.25 6ONm (44.3 Ib ft) Toctite® 243 Clutch holder (47029003000) (== p. 173) ‘Secure the nut with the lock washer. Thoroughly ol the clutch facing discs. Beginning with a clutch facing disc, alternately insert all remaining intermediate dises and clutch facing discs into the clutch basket ‘Mount pressure piece @ with the axial bearing,15 ENGINE 15.5.15 Installing the clutch cover, so6iet-it 155.16 @ == Installing the spacer 30618010 127 ~ Position pressure cap @ — Mount screws @@ wih the washers and springs and tighten them in a cissrass patter. Guideline ‘Screw, clutch springs MS 6 Nm (4.4 It ft) = Clean the seating surfaces. = Mount dowels @ = Mount clutch cover gasket @. = Position the clutch cover ~ Mount and tighten screws @. Guidetine Sere clutch intermediate cover Me = Before mounting, grease spacer @ in area @ and O-Ring @ 170) Position the O-ring in the recess of the spacer. Long-life grease ( = Grease the shaft seal ring p.170) Longelife grease ( = Push spacer with the O-ring onto the countershaft with a twisting motion, ‘7 The recess with the O-ring faces inward ‘7 The shaft seal ring rests against the spacer along the entire circumference,15 ENGINE 155.17 Installing the stator 155.19 50617810, Position the stator. 128 Mount screws @ but do not tighten yet. Guideline Screw, grtion MB Nm Totite® 2227 systemstator (alot fo Position cable sleeve @ in the engine case. Ensure thatthe woodrult key is seated properly Grease the cone. Mount rotor @. Hold the rotor with special tool @ Holding spanner (64629012200) ( p. 178) Mount washer and nut @. Tighten the nut. Guideline Tut, rotor wax 0 Nm (44.3 it) il the upper conrod bearing and position it in the connecting rod. Position the piston. Piston marking @ must face the exhaust side. Slide piston pin @ int the connecting rod by hands15 ENGINE 129 = Cover the engine case opening with a cloth. = Poston the piston pin retainer in the 6 o'ctck or 12 oock poston 0 = Ensure that the piston pin retainers seated propel on bth ss O = Remove te th, 2o30 15.5.20 Installing the cylinder = Clean the seating surfaces. = Poston the new cylinder base gasket @ Info It neither the piston, cylinder, crankshaft, or engine case need to be changed, the same gasket thickness can be used as before. = Gil the cylinder and piston, = Position the piston ring, ‘Y The anti-rotation lock engages in piston ring end @. = Slide the cylinder over the piston. ~ Push the cylinder down carefully = Mount nuts @ on both sides and tighten in a crisscross pattern. Guideline ‘Nats, cylinder base ue 20 Nm (14.8 off) 15.5.21 Checking the X-distance Info The X-distance 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. If the 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. ~ Mount special to! @ onthe eyincer ‘Adjusting gauge (47029006000) (== p. 174) Info TH Mount the speciat tool with marking cylinder height onto the cylinder. Position the piston at top dead center = Check the X-distance. Info The piston must not lift the gauge off of the cylinder. X-distance (distance from adjusting | =0.10... 0.00 mm (-0.0039....0 in) gauge to piston) + If the specified value is not attained: = Adjust the X-distance, (© p. 130)15 ENGINE 15.5.22 Adjusting the X-distance 130 ‘The X-distance is adjusted by inserting cylinder base gaskets of various thicknesses. 155.23 Setting the ignition 15.5.24 Adjusting the Z-distance Preparatory work = Check the X-distance. ( p. 129) = Remove the cylinder. (= p. 92) Main work = Replace cylinder base gasket @ by a clincer base gasket of the appropriate size Finishing work = Install the cylinder. (= p. 129) = Position the piston at top dead center. ~ Mount special too! @ on the cylinder ‘Adjusting gauge (47029006000) ("= p. 174) Info Mount the special tool with marking ignition onto the cylinder. — Turn the crankshaft counterclockwise until the top edge of the piston is resting against the special tool. = Turn the stator until markings @ anc @ are aligned ~ Tighten screws @. Guidetine Screw, ignition Me 6Nm Loctite® 222 system/stator (4.4 tbe fo) © Info The Z-distance is the distance from the lower edge of the control flap to the upper edge of the cylinder, measured in the mid dle of the exhaust port.15 ENGINE 306159-10 f206156-10, 131 Loosen serow @. Remove serew @ Mount serew @ but do not tighten yt Guideline Screw, control flap, M5 @Nm exhaust control (5.9 ibe ft) Loctite® 243 ‘Swing control flap @ upward and position special tool @. ‘Swing the control flap downward and let it rest against the special tool Let stop plate @ cestaesinst stop ecge @ Tighten screw @ Guideline Screw, stop plate of exhaust control [ WB Tighten screw @ Guideline ‘Screw, control flap, oy eNm exhaust control (5.9 Ibe ft 6 Nem (4.4 IF) Loctite® 243 /306156-10, Mi. Check the Z-distance. Guideline Zedistance (height of control flap) ‘32 mm (1.26 in) Clean the sealing surfaces and mount gasket @. Push the control flap dovin all the way to the stop. ‘Mount ball socket @. Info The linkage may only be pulled upward slightly. The control flap must not be swung upward. Check the movement of the linkage. Guidetine S1mm(s0.04 in) > tf the linkage is pulled up futher: ~ Locsen look nut @ = Remove the ball socket = Turn the ball socket until the linkage reaches the right length = Mount the ball socket an tighten the lock nut Position the cover Mount and tighten screws @®. Guideline Screw, exhaust control cover M5 Nin (4.4 IF15 ENGINE 155.25 155.26 Installing the kick starter Installing the alternator cover 155.27 Installing the cylinder head f206133-10, 155.28 Installing the spark plug Position the kick starter. ‘Mount and tighten screw @ with the washer. Guideline 132 ‘Screw, kick starter Me 12Nm (8.9 Ib FY) Loctite® 243" Postion the alternator cover Mount and tighten sens @ Guideline Screw, alternator cover Me 8 Nm (5.9 IbF A) Mount the cylinder head gaskets. © Info Put the cylinder head in place. Ensure that the dowel pins are seated properly ‘Mount screws @ with the washers and tighten them in a crisscross pattern. Guideline [ Screw, evinder head Me TONm (7.4 IBF) Info Always use new screws and washer: Mount and tighten spark plug @. Guideline Spark plug MIAx1.25 20Nm (14.8 ff15 ENGINE 133 15.5.29 Installing the oil drain plug, — Mount and tighten the oil drain plug @ with the magnet and a new seal ring. Guideline Oil drain plug with magnet Mio 20m (24.8 tof fo = Mount clutch push rod @ will the ball 15.5.31 Installing the engine sprocket = Slide on the engine sprocket withthe collar facing the engine. = Mount lock ring @. 15.5.32 Removing the engine from the engine assembly stand = Remove screw connections @. = Remove the engine from the engine assembly stand. : zg 30615810,16 CARBURETOR 134 Danger Fire hazard Fuel is highly flammable, ‘The fuel in the fuel tank expands when warm and can escape if overfilled. = Do not refuel the vehicle inthe vicinity of open flames or it cigarettes Switch off the engine for refueling, = Make sure that no fuel is spilled; particularly not on hot parts of the vehicle. = Hany fuel is spilled, wipe it off immediately Observe the specifications for refueling. Warning Danger of poisoning Fuel is poisonous and a health hazard, Avoid skin, eye and clothing contact with fuel = Immediately consult @ doctor if you swallow fuel. = Do not inhale fuel vapors. = Incase of skin contact, rinse the affected area with plenty of water. Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes. = Change your clothing in case of fuel spills on them, = Keep fuels correctly in a suitable canister, and out of the reach of children. = Close fuel tap, = Pull off fuel line @. Info HB Remaining fuel may flow out of the fue! hose = Loosen hose clip @ = Loosen hose clip .16 CARBURETOR 135, Pall off vent hose @ Pall the carburetor out of the intake flange toward the rea. Pall the carburetor forward out of the intake flange and hang it to one side Remove screws @ Remove the throttle slide cover and pull the throttle slide out of the carburetor. Drain the remaining fuel. Pl back the throtle slide pring and plastic lock @. Detach throttle cable wire @. Remove the throttle side. ‘Mount the throttle slide spring with the plastic lack on the throttle cable wire and push it back, Attach trttle cable wire @ Postion plastic retainer @ Postion the throttle slide spring Postion the tre side and carburetor cover Mount and tighten screns ©. Guideline Screw, carburetor cover we Shim G2 BFR) Mount vent nose @ Postion the carburetor inthe intake flange. Push the carburetor back and positon i in the intake Mange.16 CARBURETOR 136 ~ Position ana tignten hose clip @ ~ Position and tighten hose clip @, = Mount fet tine @ Condit The carburetor has been removed. Detach the hoses from the carburetor. 306306-10 = Remove screws @. ~ Remove the float chamber with the hoses.16 CARBURETOR = Remove fulcrum pin @ ~ Remove slot @ and float needle vale. = Remove main jet @. ~ Remove needle et © = Remove iding jet @. = Note down the setting of the idle air adjusting screw @. = Remove the ial ar adjusting serew with the On Info To not mispiace the sering. = Remove choke slide @. 13716 CARBURETOR 138 — Pull jet needle @ out pf the throttle slide. = Mount and tighten choke slide @. Guideline Choke slide io SNm G7 bw) = Mount ile air adjusting screw @ with the spring and O-ring, ‘ternative 1 Set the dle air adjusting screw othe spected value Guideline Tale air adjusting sre Open Tanne Aernative 2 Set the idle air adjusting screw othe value noted down during disassembly ~ Mount and tienen idling jet © Guideline Tang et WOT Nm aS wh = Mount and tighten needle jet @ Guideline Needle jet 35 Nem (2.58 If ~ Mount and tighten main jet @. Guideline Main jet M5x0.75 2Nm(1.5 FD16 CARBURETOR 138 ~ Position float needle vaive and leat @. — Mount fulerum pin @ = Chech/adjus the flat level. (© p. 141) = Position the hoses onthe carburetor. = Position the float chamber. = Mount and tighten screws @. Guideline [oii catwrtrscews [We tS TD = Mount the hoses. ~ Position jet needle @ in the throttle slide. Condition The carburetor has been removed.16 CARBURETOR 140 = Disassemble the carburetor. (= p. 136) 9 = Check the jet needle. (28 p. 140) & = Check the throttle slide. (= p, 140) co = Check the float needle valve. (= p. 140) a = Check the choke slide. (®* p. 141) $: = Assemble the carburetor. (© p. 138) Condition ‘The jet needle has been removed, = Check whether the jet needle is bent or ifthe coating is worn off. » Ifthe jet needle is bent or ifthe coating is damaged or worn: = Change the jet needle. Check that the needle clip is firmly seated. » Ifthe needle clip is not firmly seated: = Change the needle clip or jet needle. Conditior 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. = Check the coating of the throttle slide for damage and wear. » Ifthe coating is damaged or worn: = Change the throttle slide. Condition The float needle valve has been removed. = Check the float needle valve and valve seat for deposits. » If there are deposits: = Clean the valve seat. Clean the float needle valve or change It. = Check the float needle valve for wear and the sealing surfaces for notches. > Ifthe sealing surface is damaged or worn: = Change the float needle valve. 700057-10)16 CARBURETOR 141 (16.9 Checking the choke side Condition The choke slide has been removed. ‘Check the choke slide for smooth operation, » If the choke slide is stiff and soiled: = Clean the choke slide and check its activation, ‘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 collar and locking mechanism. If the collar is damaged or britte, or if the locking machanism is not functional: = Change the choke slide. Condition The carburetor and float chamber have been removed. Tilt the carburetor sideways while preventing the fulcrum pin from falling out. Tilt the carburetor until the float is resting against the float needle valve but the float needle valve is not squeezed. » If, when in this position, the edge of the float is not parallel (max. 1° deviation in an upward direction) to the sealing surface of the float housing: ~ Adjust the float level by bending float lever @. ~ Sere in ile ar adjusting serew @ all the way anc tum i to te specified basic positon Guiding Tale air adjusting sere Open 1.5 turns = 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 and death. = Always make sure there is sufficient ventilation when running the engine. = Use an effective exhaust extraction system when starting or running the engine in an enclosed space, ~ Adjust the ile speed with adjusting screw @ Guideline Choke function deactivated ~ The choke levers pushed n tothe stop. ial speed 1,400... 1,500 rpm ~ Turn fle ar adjusting serew @ stowiy in a clockwise cretion until the cle speea bens to fal. ~ Note the postion and tum the ile air adjusting screw slowly counterclockwise uti the cle speed fas agin = Adjust to the point between these two postions with the highest ile speed.16 CARBURETOR Info Tithe engine speed rises considerably, reduce the idle speed to a normal level and repeat the above steps. If the procedure described here does not lead to satisfactory results, the cause may be a wrongly dimensioned idling jet. It 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. Aiter changing the idling jet, start from the beginning with the adjusting steps. Following extreme air temperature or altitude changes, adjust the idle speed again, Danger Fire hazard Fuel is highly flammable, ‘The fuel in the fuel tank expands when warm and can escape if overilled. = Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. = Switch off the engine for refueling. = Make sure that no fuel is spilled: particularly not on hot perts of the vehicle. = Hany fuel is spilled, wipe it off immediately. = Observe the specifications for refueling. a Warning Danger of poisoning Fuel is poisonous and a health hazard, = Avoid skin, eye and clothing contact with fuel = Immediately consult a doctor if you swallow fuel. = Do not inhale fuel vapors, = Incase of skin contact, rinse the affected area with plenty of water. Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes. = Change your clothing in case of fuel spills on them, = Keep fuels correctly ina suitable canister, and out of the reach of children. Warning Environmental hazard improper handling of fuel is a danger to the environment. = Do not alow fuel to enter the groundwater, the sol, or the sewage system. Info Cary out this work with a cold engine. Water in the float chamber results in malfunctioning Preparatory work = Turn tap handle @ on the uel tp tothe OFF poston (Figure c00462-10"" p. 59 7 No more fuel flows from the fuel tank to the carburetor. Main work = Place a cloth beneath the carburetor to soak up emerging fuel. = Remove plug @. Completely drain the fuel = Mount and tighten screw plug @17. CLUTCH 143 17.1 Checking the fuid level of the hydraulic clutoh © Info The ttuid tevet rises with increasing wear of the clutch facing discs. = Move the clutch uid reservoir mounted on the handlebar to a horizontal positon = Check the fluid level in viewer @. Ifthe fluid has dropped below marking @ inthe viewer; = Correct the fluid level ofthe hydraulic elutch. (=® p. 143) tation Brake fluid causes skin irritation. = Keep brake fluid out of the reach of children Wear suitable protective clothing and safety glasses. = Do not allow brake fluid to come into contact with the skin, the eyes or clothing, = Consult 2 doctor immediately if brake fluid has been swallowed, = Rinse the affected area with plenty of water in the event of contact with the skin. = Rinse eyes thoroughly with water immediately and consult @ doctor if brake fluid comes into contact with the eyes. = If brake fluid spills on to your clothing, change the clothing. Info ‘The fluid level rises with increasing wear of the clutch facing discs. Never use DOT 5 brake fluid. Its silicone-based and purple in color, Ol seals and clutch lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid attacks paint. Only use clean brake fluid from a sealed container. = Move the clutch fluid resewoir mounted onthe hanclabar to a horizontal position, = Remove screws @. — Remove cover @ with membrane @. = Correct the fluid up to level @. Guideline Level @ (fluid level below container | 4 mm (0.16 in) rim) Brake fluid DOT 4/ DOT 6.1 (= p. 168) = Posi n the cover with the membrane. Mount and tighten the screws. © Info T Glean up overflowed or spilled brake fluid immediately with water.17 CLUTCH 144 Warning ‘Skin ination Brake fluid causes skin irritation Keep brake fluid out of the reach of children. ‘Wear suitable protective clothing and safety glasses. Do not allow brake fluid to come into contact with the skin, the eyes or clothing. Consult a doctor immediately if brake fluid has been swallowed, Rinse the affected area with plenty of water in the event of contact with the skin. Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes. If brake fluid spills on to your clothing, change the clothing. Warning BN roma srt Harris stances ane entonmel dma. Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., corectly and in compliance with the applicable regu- lations. Info Never use DOT 5 brake fluid. Itis silicone-based and purple in color, Oil seals and clutch lines are not designed for DOT 5 brake fluid ‘Avoid contact between brake fluid and painted parts. Brake fluid attacks paint. Only use clean brake fluid from a sealed container. = Move the clutch fluid reser mounted on the handlebar to a horizontal postion, = Remove seens @ ~ Remove cover @ with membrane © Fill bleeding syringe @ with the appropriate hydraulic fluid. Bleed syringe (50329050000) ("= p. 174) Brake fluid DOT 4 /DOT 5.1 (= p. 168) ~ On the clutch slave cylinder, remove bleeder screw @ and mount bleeding syringe @. = Inject he tquidinto te system unt it escapes rom opening @ ofthe maser cylinder without bubbles Now and then, eta ud from the master cylinder resent prevent vero Remove the bleeding syringe. Mount and tighten screws bleeder sen - Correct the fluid level of the hydraulic clutch. Guideline Flu evel below container ti Tam Oem = Position the cover with the membrane. Mount and tighten the screws. Info T Clean up overflowed or spilled brake fluid immediately with water.