TABLE OF CONTENTS 4
16.4.35 Disassembling the countershaft.................. 148
16.4.36 Checking the transmission......................... 148
16.4.37 Assembling the main shaft......................... 150
16.4.38 Assembling the countershaft...................... 151
16.4.39 Checking the starter drive .......................... 152
16.4.40 Checking freewheel ................................... 153
16.4.41 Removing freewheel .................................. 153
16.4.42 Installing freewheel................................... 153
16.5 Assembling the engine .................................. 154
16.5.1 Installing the transmission shafts ............... 154
16.5.2 Installing crankshaft and balancer shaft...... 155
16.5.3 Installing the left engine case .................... 156
16.5.4 Installing the oil pumps............................. 157
16.5.5 Installing locking lever .............................. 158
16.5.6 Installing shift drum locating ..................... 158
16.5.7 Installing shift shaft.................................. 158
16.5.8 Installing the starter drive.......................... 158
16.5.9 Installing the primary gear ......................... 159
16.5.10 Installing the clutch basket........................ 159
16.5.11 Installing the spacer and spring.................. 161
16.5.12 Installing the clutch cover ......................... 161
16.5.13 Installing the ignition pulse generator ......... 162
16.5.14 Installing timing chain and timing chain
sprocket................................................... 162
16.5.15 Installing the timing chain rails.................. 162
16.5.16 Installing the rotor .................................... 163
16.5.17 Adjusting crankshaft position sensor
distance................................................... 163
16.5.18 Setting engine to top dead center............... 164
16.5.19 Mounting the water pump cover ................. 164
16.5.20 Installing piston........................................ 164
16.5.21 Installing the cylinder head........................ 166
16.5.22 Installing the camshafts ............................ 167
16.5.23 Installing timing chain tensioner ................ 167
16.5.24 Checking valve clearance........................... 168
16.5.25 Adjusting the valve clearance..................... 169
16.5.26 Installing the spark plugs........................... 170
16.5.27 Installing the thermostat............................ 170
16.5.28 Installing the oil filter................................ 170
16.5.29 Installing the gear position sensor .............. 171
16.5.30 Installing the spacer.................................. 171
16.5.31 Installing the alternator cover..................... 171
16.5.32 Installing oil screens ................................. 172
16.5.33 Installing the starter motor......................... 172
16.5.34 Installing the valve cover ........................... 173
16.5.35 Removing the engine from the engine
assembly stand......................................... 173
17 CLUTCH.................................................................. 174
17.1 Checking/rectifying the fluid level of the
hydraulic clutch............................................ 174
17.2 Changing the hydraulic clutch fluid ................ 174
18 SHIFT MECHANISM................................................. 175
18.1 Changing the gear position sensor................... 175
18.2 Programming the gear position sensor ............. 177
19 WATER PUMP, COOLING SYSTEM ............................ 178
19.1 Draining the coolant...................................... 178
19.2 Filling/bleeding the cooling system ................. 178
19.3 Checking the antifreeze and coolant level ........ 179
19.4 Checking the coolant level ............................. 180
20 LUBRICATION SYSTEM............................................ 181
20.1 Oil circuit..................................................... 181
20.2 Checking the engine oil level.......................... 181
20.3 Checking the engine oil pressure .................... 182
20.4 Changing the engine oil and filter, cleaning
the oil screens .............................................. 183
20.5 Draining the engine oil .................................. 183
20.6 Removing the oil filter ................................... 184
20.7 Installing the oil filter.................................... 184
20.8 Cleaning the oil screens................................. 185
20.9 Filling up with engine oil ............................... 186
20.10 Adding engine oil.......................................... 186
21 IGNITION ................................................................ 187
21.1 Alternator - checking the stator winding .......... 187
21.2 Checking the spark plug connector ................. 187
21.3 Ignition coil – checking the secondary
winding........................................................ 188
22 THROTTLE VALVE BODY .......................................... 189
22.1 Performing the initialization run ..................... 189
23 TECHNICAL DATA.................................................... 190
23.1 Engine ......................................................... 190
23.2 Engine tolerance, wear limits ......................... 190
23.3 Engine tightening torques .............................. 192
23.4 Capacities .................................................... 193
23.4.1 Engine oil ................................................ 193
23.4.2 Coolant.................................................... 193
23.4.3 Fuel ........................................................ 193
23.5 Chassis ........................................................ 194
23.6 Electrical system........................................... 194
23.7 Tires............................................................ 195
23.8 Fork............................................................. 195
23.9 Shock absorber............................................. 195
23.10 Chassis tightening torques ............................. 196
24 CLEANING/PROTECTIVE TREATMENT....................... 198
24.1 Cleaning the motorcycle ................................ 198
24.2 Checks and maintenance steps for winter
operation...................................................... 199
25 STORAGE................................................................ 200
25.1 Storage ........................................................ 200
25.2 Preparing for use after storage........................ 200
26 SERVICE SCHEDULE ............................................... 201
26.1 Service schedule........................................... 201
27 WIRING DIAGRAM ................................................... 202
27.1 Page 01 of 11 .............................................. 202
27.2 Page 02 of 11 .............................................. 204
27.3 Page 03 of 11 .............................................. 206
27.4 Page 04 of 11 .............................................. 208
27.5 Page 05 of 11 .............................................. 210
27.6 Page 06 of 11 .............................................. 212
27.7 Page 07 of 11 .............................................. 214
27.8 Page 08 of 11 .............................................. 216
27.9 Page 09 of 11 .............................................. 218
27.10 Page 10 of 11 .............................................. 220
27.11 Page 11 of 11 .............................................. 222
28 SUBSTANCES ......................................................... 224
29 AUXILIARY SUBSTANCES ........................................ 226
30 SPECIAL TOOLS ...................................................... 228
31 STANDARDS ........................................................... 241
INDEX ............................................................................ 242
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