09913-10750:Adaptor

PERIODICMAINTENANCE2·31

OILPRESSURECHECK

Checktheengineoilpressureperiodically.Thiswillgiveagoodindicationoftheconditionofthemovingparts.

OILPRESSURESPECIFICATION

200-500kPa(2.0-5.0kgf/cm2,28-71psi)at3000r/rnin.,Oiltemp.at60°C(140°F)

Iftheoilpressureislowerorhigherthanthespecification,thefollowingcausesmaybeconsidered.LOWOILPRESSURE

"Cloggedoilfilter

*Oilleakagefromtheoilpassage

*Damaged0-ring

"Defectiveoilpump

*Combinationoftheaboveitems

HIGHOILPRESSURE

'*Engineoilviscosityistoohigh

•Cloggedoilpassage

'*Combinationoftheaboveitems

OILPRESSURETESTPROCEDURE

Starttheengineandcheckiftheoilpressureindicatorlightisturnedon.Ifthelightstayson,checktheoilpressureindicatorlightcircuit.IfthecircuitisOK,checktheoilpressureinthefol·lowingmanner.

•RemovethemainoilgalleryplugG).

•Installtheoilpressuregaugeandadaptorintothemainoilgallery.

•Warmuptheengineasfollows:

Summer:10min.at2000r/min.Winter:20min.at2000r/min.

•Afterwarmingup,increasetheenginespeedto3000r/min.(observethetachometer),andreadtheoilpressuregauge.

1@109915-74520:Oilpressuregaugehose

09915-74540:Oilpressuregaugeattachment

09915-77330:Meter(forhighpressure)

~Oilgalleryplug(M16):35N·m(3.5kgf·m,25.5lb-ft)

ENGINE

CONTENTSENGINECOMPONENTSREMOVABLEWITH

THEENGINEINPLACE...................................................................3-2

ENGINEREMOVALANDREINSTALLATION3-3

ENGINEREMOVAL3-3

ENGINEREINSTALLATION	3-11
ENGINEDISASSEMBLY..................................................................	3-15
ENGINECOMPONENTSINSPECTIONANDSERVICE.................	3-28
PAIRVALVE	3-28
CYLINDERHEADCOVER............................................................	3-29
CAMSHAFT...................................................................................	3-29
CAMCHAINTENSIONADJUSTER..............................................	3-31
CAMCHAINTENSIONER.............................................................	3-31
CAMCHAINGUIDE	3-31
CYLINDERHEADANDVALVE.....................................................	3-32
CLUTCH.........................................................................................	3-42
OILPUMP	3-43
STARTERCLUTCH.......................................................................	3-43
GENERATOR.................................................................................	3-43
WATERPUMP................................................................................	3-43
GEARSHIFTSYSTEM...................................................................	3-44
OILPRESSUREREGULATOR.....................................................	3-45
OILSTRAINER	3-45
TRANSMISSION............................................................................	3-46
CYLINDER	3-49
PISTONANDPISTONRING.........................................................	3-50
CRANKCASE.................................................................................	3-53
CRANKSHAFTANDCONROD.....................................................	3-59
CRANKSHAFTJOURNALBEARING..........................................	3-62
CRANKSHAFTTHRUSTBEARING..............................................	3-64
ENGINEREASSEMBLY...................................................................	3-66

3·2ENGINE

ENGINECOMPONENTSREMOVABLEWITHENGINEINPLACE

Thepartslistedbelowcanberemovedandreinstalledwithoutremovingtheenginefromtheframe.Refertopagelistedineachsectionforremovalandreinstallationinstructions.

ENGINECENTER

^{ITEMREMOVALINSPECTIONREINS}TALLATION^{PAIRvalvec:::?'3-15c:::?'3-28c:::?3·97}

^{Startermotorc:::?3-15c:::?'7-12}_{c::::::r3·97}

_{Breathercoverc::::::r3.24--c::::::r3-77}

Thermostat_{c:::::r3-17c:::::r5-10c:::::r3-90}

_{Cylinderheadcoverc:::::r3-15c:::::r3-29c:::::r3-96}

Camshaftc:::::r3-16_{c:::::r3.29c:::::r3-91}

Intakepipe^----_c:::::r3-41

^{Oilfilterc::::::r3.24}_--c:::::r3-76

^{Oilcoolerc::::::r}3-24--_c:::?'3-76

^{Oilpanc:::?'3-25--c::::::r}3-75

ENGINERIGHTSIDE

^{ITEMREMOVALINSPECTIONR}EINSTALLATIONExhaustpipeandmuffler_{c:::?3-5--c:::::r3-14}

Camchaintensionadjuster_{c:::::r3-16c::::::r3-31c::::::r3-94}

Clutchcoverc:::::r3-18_{--c:::::r3-88}

Clutch(plates)_{c:::::r3·18c:::::r3-42c::::::r3-86}

^{Primarydrivengearc:::::r}3-19--_c:::::r3-84

^{Oilpumpc:::?'}3-20_{c:::?'3-43c:::::r3-84}

Gearshiftshaft_{c::::::r3-20c::::::r3-44c:::::r3-84}

^{Starteridlegearcoverc:::::r}3-22--_c:::::r3-82

^{Starteridlegearc::::::r3-22--c:::::r3-81}

_{Starterclutchc:::::r3-23c:::::r3-43c:::::r3-81}

CKPsensor_{c:::::r3-23c:::::r4-35c:::?'3-80}

^{Primarydrivegear}_{c:::::r3-23--c:::::r3-81}

^{Camchainandcamchaintensionerc:::?'3-22c:::?3-31c:::::r}3-80

ENGINELEFTSIDE

^{ITEMREMOVALINSPECTIONR}EINSTALLATION^{Enginesprocketc:::?3-8--}c:::::r3·13

^{Gearpositionsensor}_{c:::?3-24c:::?4-49c::::::r3-77}

^{Generator(cover)c::::::r}3.23_{c::::::r3.43c:::::r3-79}

^{Generatorrotor}_{c:::::r3-23--c:::::r3-79}

^{Waterpumpc:::::r3-23c:::?5-14c:::::r3-78}

ENGINEREMOVALANDREINSTALLATION

ENGINEREMOVAL

Beforetakingtheengineoutoftheframe,washtheengineusingasteamcleaner.Engineremovalissequentiallyexplainedinthefollowingsteps.Reinstalltheenginebyreversingtheremovalpro•cedure.

•Removetheundercowlings.(c::::T'6-3)

•Removethefrontandrearseats(seattailcover).(c::::T'6-6)

•Removethefueltank.(c::::7"4-52)

•Disconnectthebattery8leadwire.

•Drainengineoil.(c::::T'2-13)

•Drainenginecoolant.(c::::T'2-18)

•Removetheaircleanerbox.(c::::::t4-62)

•Removethethrottlebody.(c::::::t4-63)

RADIATOR

•Disconnectthereservetankhose.

•Disconnecttheradiatorinlethoses.

•Disconnectthecoolingfanthermo-switchcoupler(})andcool•

ingfancoupler(2).

•Disconnectthehorncoupler®·

•Removetheradiatorbolt.

•Removetheradiatorandhorn.

IACAUTIONI

Becarefulnottobenttheradiatorfin.

•Removethefrontenginecover.

EXHAUSTPIPEANDMUFFLER

•Removetheexhaustpipebolts.

•Removethemufflermountingboltandnut.

•Removetheexhaustpipe/muffler.

•RemovetheradiatormountingbracketG).

ELECTRICPARTS

•DisconnecttheoilpressureswitchleadwireG)andremoveitfromtheclamps.

•Disconnectthestartermotorleadwire~.

•Disconnectthegroundleadwire®·

•Disconnectthecrankshaftpositionsensorcoupler@.

•Disconnectthegearpositionswitchcoupler®·

•Disconnecttheenginecoolanttemperaturesensorcoupler@.

•Disconnectthegeneratorcoupler(!).

•Disconnecttheleadwirecouplersfromeachignitioncoil/plugcapandcamshaftpositionsensor.

ACAUTIONI

Donotremovetheignitioncoil/plugcapbeforediscon•

nectingitsleadwirecoupler.

•Removetheignitioncoils/plugcaps.

IACAUTIONI

*Donotpryuptheignitioncoil/plugcapwithadriverorabartoavoiditsdamage.

*Becarefulnottodroptheignitioncoil/plugcaptopre•