15Mm(0.6in)fromthepistonskirtend.

•Ifthemeasurementislessthanthelimit,replacethepiston.

DPistondiameter:

ServiceLimit:66.880mm(2.6331in)

at15mm(0.6in)fromtheskirtend

1r'OOL109900-20203:Micrometer(50-75mm)

PISTONTOCYLINDERCLEARANCE

•Subtractthepistondiameterfromthecylinderborediameter.

(c:::::T3-50)

•Ifthepistontocylinderclearanceexceedstheservicelimit,replacethecylinderandthepiston.

gPistontocylinderclearance:

ServiceLimit:0.120mm(0.0047in)

PISTONPINSANDPINBORE

•Measurethepistonpinboreinsidediameterusingthesmallboregauge.

•Ifthemeasurementisoutofspecificationsreplacethepiston.

n'Mu09900-20602:Dialgauge(1/1ooomm)

09900-22401:Smallboregauge(10-18mm)

gPistonpinborel.D.:

ServiceLimit:14.030mm(0.5524in)

•Measurethepistonpinoutsidediameteratthreepositionsus•

ingthemicrometer.

•Ifanyofthemeasurementsareoutofspecification,replacethepistonpin.

!Ml!09900-20205:Micrometer(0-25mm)

gPistonpinO.D.:

ServiceLimit:13.980mm(0.5504in)

_J15mm

PISTONRINGTOGROOVECLEARANCE

-

•Measurethesideclearancesofthe1stand2ndpistonringsusingthethicknessgauge.

•Ifanyoftheclearancesexceedthelimit,replaceboththepis•

tonandpistonrings.

ITMI09900-20803:Thicknessgauge

09900-20205:Micrometer(0-25mm)

~Pistonringtogrooveclearance:

ServiceLimit(1st):0.18mm(0.0071in)(2nd):0.15mm(0.0059in)

~Pistonringgroovewidth:

Standard(1st):1.01-1.03mm(0.0398-0.0406in}(2nd):0.81-0.83mm(0.0319-0.0327in)(Oil):1.51-1.53mm(0.0594-0.0602in)

~Pistonringthickness:

_{Standard(1st):0.97-0.99mm(0.0382-0.0390in)}

^{{2nd):o.n-0.79mm(0.0303-0.0311in)}

PISTONRINGFREEENDGAPANDPISTONRINGENDGAP

•Measurethepistonringfreeendgapusingverniercalipers.

•Next,fitthepistonringsquarelyintothecylinderandmeasurethepistonringendgapusingthethicknessgauge.

•Ifanyofthemeasurementsexceedtheservicelimit,replace

thepistonringwithanewone.

!TMI09900-20102:Verniercalipers

~Pistonringfreeendgap:

ServiceLimit(1st):5.8mm(0.23in)(2nd):7.4mm(0.29in)

u'ooti09900-20803:Thicknessgauge

~Pistonringendgap:

ServiceLimit(1st):0.50mm(0.020in)(2nd):0.50mm(0.020in)

PISTONRINGREASSEMBLY

•Installthepistonringsintheorderofoilring,2ndringand1string.

•ThefirstmembertogointotheoilringgrooveisaspacerG).

Afterplacingthespacer,fitthetwosiderailsczi.

NOTE:

Sidedesignations,topandbottom,arenotappliedtothespacerandsiderails:youcanpositioneacheitherway.

ACAUTIONI

Wheninstallingthespacer,becarefulnottoallowitstwoendstooverlapinthegroove.

_CORRECT

•Installthe2ndringCT)andthetstring©.

NOTE:

1stringand2ndringdifferinshape.

•1stringand2ndringhaveletters"A"and"RN"markedontheside.Besuretobringthemarkedsidetothetopwhenfitting

_{themtothepiston.}

•Positionthegapsofthethreeringsasshown.Beforeinsertingeachpistonintothecylinder,checkthatthegapsaresolo•cated.

•2ndring

•Lowerside

rail

•Uppersiderail

•tstring

_IN^•Spacer

CRANKCASE

LOWERCRANKCASE

GEARSHIFTFORKANDGEARSHIFTCAMRemoval

•RemovethegearshiftcambearingretainerCDandgearshift

forkretainer(Z)fromthelowercrankcase.

•Removethegearshiftforkshaftsandgearshiftforksfromthelowercrankcase.

•Removethegearshiftcamanditsbearing.

GEARSHIFTFORKTOGROOVECLEARANCE

•Usingathicknessgauge,checkthegearshiftforkclearanceinthegrooveofitsgear.

•Theclearanceforeachgearshiftforkplaysanimportantroleinthesmoothnessandpositivenessoftheshiftingaction.

& Shiftforktogrooveclearance:ServiceLimit:0.50mm(0.020in)

nTuli09900-20803:Thicknessgauge

•Iftheclearancecheckedisnotedtoexceedthelimitspecified,replacetheforkoritsgear,orboth.

GEARSHIFTFORKGROOVEWIDTH

•Measurethegearshiftforkgroovewidthusingtheverniercali•

pers.

BShiftforkgroovewidth:

Standard:5.0-5.1mm(0.197-0.201in)

1&it109900-20102:Verniercalipers

GEARSHIFTFORKTHICKNESS

•Measurethegearshiftforkthicknessusingtheverniercalipers.

BShiftforkthickness:

Standard:4.8-4.9mm(0.189-0.193in)Ifill09900-20102:Verniercalipers

•Inspectthegearshiftcambearingforabnormalnoiseandsmoothrotation.

•Replacethebearingsifthereisanythingunusual.

•InspectthegearshiftcambearingCD,gearshiftforkbearing~andgearshiftshaftbearingCT)forabnormalnoiseandsmoothrotationwhiletheyareinthecrankcase.

•Replaceabearingifthereisanythingunusual.

Bearingremoval

•Removethegearshiftforkbearingusingthespecialtool.

1r1XiL!09921-20210:Bearingremover

09930-30102:Slidingshaft

•Removethegearshiftcambearingusingthespecialtools.

1Rkih09921-20220:Bearingremoverset

09910-20115:Conrodstopper

IACAUTIONI

*Don'tdamagethecrankcasebytheconrodstopper.

_{*Becarefulnottoleanthebearingremover.}

•Removetheoilseal.

•Removethegearshiftshaftbearingusingthespecialtool.

_{!Mb09921-20220:Bearingremoverset}

^-