ENGINE 66

GEARSHIFT CAM STOPPER

• Remove the gearshift cam stopper bolt.

• When installing the gearshift cam stopper, apply a small

quantity of THREAD LOCK "1342" to the thread of the bolt

and nut.

DRIVE BELT COVER

Inspection

Inspect the oil seal for damage or wear on the lip.

If any defects are found, replace the oil seal with a new one.

DISASSEMBLY

• Remove the oil seal retainer.

• Remove the bearing together with the oil seal.

TOOL: Bearing remover set

• Remove the bearing retainers.

ENGINE 67

• Remove the bearing with the special tool.

TOOL: Bearing installer/remover set

• Remove the oil seal with the special tool.

TOOL: Bearing installer/remover set

REASSEMBLY

• Install the oil seal with the special tool.

TOOL: Bearing installer set

• Install the bearing with the special tool.

TOOL: Bearing installer set

• When installing the bearing retainers, apply a small quantity

of THREAD LOCK to the screws.

ENGINE 68

GENERATOR COVER

DISASSEMBLY

• Remove the generator stator.

• Remove the bearing together with the oil seal by the special

tool and suitable bars as shown.

TOOL: Bearing remover set

NOTE:

If there is no abnormal noise, the bearing removal is not

necessary.

• Remove the oil seal.

REASSEMBLY

• Install the bearing with the special tool.

TOOL: Bearing installer

ENGINE 69

• Apply

GREASE "A" to the oil seal lip, O-ring

and bearing.

•Install the oil seal with the special tool.

TOOL: Bearing installer set

• Install the oil seal with the special tool,

TOOL: Bearing installer set

ENGINE 70

ENGINE REASSEMBLY

Reassemble the engine in the reverse order of disassembly.

Pay special attention to the following points:

NOTE:

Apply engine oil to each running and sliding part before

reassembling.

CAUTION

Always keep the drive belt, drive face and driven face

away from any greasy matter.

ENGINE BOTTOM SIDE

CRANKSHAFT

• When mounting the crankshaft in the crankcase, it is neces-

sary to pull its left end into the crankcase by using the special

tool.

NOTE:

Use the front fork oil seal installer and suitable bars ○A as an

attachment.

TOOL Crankshaft installer

Front fork oil seal installer

CAUTION

Never fit the crankshaft into the crankcase by striking

It with a plastic mallet.

Always use the special tool, otherwise the accuracy of

the crankshaft alignment will be affected.

BALANCER

• Install the balancershaft.

• Install the key ○1 .

• Install the balancer driven gear by aligning the punched

marks.

NOTE:

The flange side of the balancer driven gear faces outside (right

side)

ENGINE 71

○

1

FRONT/REAR OUTPUT SHAFT

• Install the front and rear output shafts.

NOTE:

Be sure to fit the pin ○

crankcase.

ns 1 on the bearing into the groove of the

○

1

• Install the C-rin ○g 2 .

○

2

TRANSFER

• Install the transfer related parts.

NOTE:

High/Low gearshift fork and reverse gearshift fork are the same

parts.

• Install the transfer input shaft ○1 .

○

1

• Install the spacer ○2 and reverse idle gear.

• Install the washer 3 .

○

2

○

○

3

ENGINE 72

CRANKCASE

• Wipe the crankcase mating surfaces (both surfaces) with a

cleaning solvent.

• Fit the dowel pins onto the left half on the crankcase.

• Apply engine oil to the conrod big end and the gears.

• Apply BOND "1207B" to the mating surface of the left

crankcase.

BOND "1207B" (USA)

• Assemble the crankcase within few minutes.

NOTE:

• After crankcase screws have been tightened, check if crank-

shaft rotate smoothly.

• Fit the clamp to the bolt ○A .

• Fit the copper washer to the bolts ○B .

After the crankcase bolts have been tightened, check if the

each shaft rotates smoothly. If a large resistance is felt to

rotation, try to free the shafts by tapping them with a plastic

hammer.

ENGINE 73

○

1

OIL PUMP

• Apply a small quantity of THREAD LOCK "1342" to the

screws and install the oil pump.

• Install the washer ○1 and pin 2

THREAD LOCK "1342"

○

2

○

• Install the oil pump driven gear.

• Install the snap ring.

TOOL: Snap ring pliers

NOTE:

Pay attention to the direction of the gear.

○

1

OIL PUMP DRIVE GEAR

• Install the spacer 1

○

and pin 2

○

○

2

○

The flange side of the gear faces inside.

• Install the oil pump drive gear 3 and washer 4

NOTE:

○

3

○

○

4

• Apply THREAD LOCK "1303" to the oil pump drive

gear bolt.

• Tighten the bolt to the specified torque by engaging a rag

between the gears as shown.

Oil pump drive gear bolt: 50 N m (5.0 kgf-m, 36.0 Ib-ft)

THREAD LOCK "1303"

ENGINE 74

CAM CHAIN

• Install the cam chain.

CLUTCH SHOE

• Apply THREAD LOCK SUPER "1303" to the clutch shoe nut.

• Install the clutch shoe assembly and tighten the clutch shoe

nut to the specified torque with the special tool.

Clutch shoe nut: 120 N m (12.0 kgf-m, 87.0 Ib-ft)

THREAD LOCK SUPER "1303"

TOOL: Rotor holder

CAUTION

The clutch shoe nut has left-hand threads.

• Install the one way clutch with facing the "OUTSIDE" mark

outside.

"OUTSIDE

• Install the clutch housing/shaft.

①

OUTPUT SHAFT HOUSING

• Install the dowel pins 1

○

• Apply THREAD LOCK "1342" to the bolts and install the out-

put shaft housing.

Output shaft housing bolt: 26 N m (2.6 kgf-m, 19.0 Ib-ft)

ENGINE 75

• Install the breather pipe.

NEUTRAL SWITCH

• Install the springs and switch contacts.

• Install the neutral switch.

CLUTCH HOUSING CASE

• Install the dowel pins and new gasket.

• Tighten the clutch housing case bolts.

• Install the collar.

NOTE

Use a new O-ring and apply GREASE "A" to it.

ENGINE 76

CLUTCH SPACER

• Install the clutch spacer

FIXED DRIVE FACE

• Install the fixed drive face ○

1

.

○

1

MOVABLE DRIVE/DRIVEN FACE AND DRIVE BELT

• Install the drive belt, as low as possible, between the

movable driven face and fixed driven face by tapping with a

plastic mallet.

CAUTION

• The drive belt should be installed so that the

arrows on the drive belt periphery point in the

normal turning direction.

• The drive belt contact surface of the driven face

should be thoroughly cleaned.

• Install the movable drive space .

ENGINE 77

MOVABLE DRIVE FACE

• Install the movable drive face assembly.

• Tighten the movable drive face nut to the

specified torque with the tool.

Movable drive face nut: 115 Nm (11.5 kgf-m, 83.0 Ib-ft)

• Install the movable driven face assembly.

• Tighten the movable driven face nut to the

specified torque with the tool.

Movable driven face nut: 115 N m (11.5 kgf-m, 83.0 Ib-ft)

NOTE:

Turn the fixed drive face until the belt is seated in and both the drive

and driven faces will move together smoothly without slip.

ENGINE 78

CLUTCH COVER

• Install the new gasket and dowel pins.

• Install the clutch cover.

WATER PUMP DRIVE/DRIVEN GEAR

○ and water pump driven gear.

NOTE:

Pay attention to the direction of the gear.

• Install the pin 1

○

1

• Install the snap ring.

TOOL: Snap ring pliers

• Install the pin 1 .

○

1

○

• Install the water pump drive gear.

NOTE:

Pay attention to the direction of the gear.

• Install the snap ring.

TOOL: Snap ring pliers

GENERATOR

• Install the washe 1 .

er

○

ENGINE 80

• Install the starter driven gear ○1 .

• Install the key 2

○

NOTE:

Degrease the tapered portion of the generator rotor assembly

and also the crankshaft. Use nonflammable cleaning solvent to

wipe off the oily or greasy matter to make these surfaces com-

pletely dry.

• Install the generator rotor assembly.

CAUTION

Make sure that the one way clutch on the crankshaft

rotor is fitted into the generator rotor properly.

• Tighten the generator rotor nut to the specified torque with

an offset wrench.

Generator rotor nut: 160 N m (16.0 kgf-m, 115.5 Ib-ft)

GEARSHIFT

• Install the washer ○1 .

• Install the cam driven gear ○2 .

• Reassemble the gearshift shaft.

• Install the gearshift by aligning the punched mark ○A with

the center of the cam driven gear.

○

A

ENGINE 81

STARTER DRIVEN GEAR/IDLE GEAR

• Install the starter driven gear and idle gear.

GENERATOR COVER

• Install the dowel pins and new gasket.

• Tighten the generator cover bolt.

STARTER CUP

• Install the magneto cover.

STARTUP DISK

• Install the startup disk nut with tool.

• Install the startup disk

RECOIL HAND-OPERATED

• Install the RECOIL HAND-OPERATED.