1
TABLE OF CONTENTS
FOREWORD ................................................ 3
SPECIAL TOOLS REQUIRED .......................... 4
TECHNICAL DATA ........................................ 5
ENGINE ..................................................... 5
CHASSIS ................................................... 6
FORK ......................................................... 6
SHOCK ABSORBER ................................. 6
CHASSIS ..................................................... 7
❱❘
Front end .................................................... 7
1.1
Wheel bearings change ................... 7
1.2
Front brake disc change : ............... 7
1.3
Fork disassembly and steering head
bearings change ........................................... 8
1.4
TECH fork servicing ........................ 9
1.4.1
Right side oil change ....................... 9
1.4.2
Left side oil change ........................ 10
❱❘
Rear end .............................................. 12
2.1
Wheel bearings change ................. 12
2.2
Brake disc change ......................... 13
2.3
Swingarm bearings check ............. 13
2.4
Suspension linkage check ............ 14
OPERATIONS REQUIRING THE
REMOVAL OR NOT OF THE ENGINE .... 15
ENGINE REMOVAL/FITTING .................. 16
❱❘
Engine removal ................................... 16
❱❘
Fitting the engine in the frame ........... 16
ENGINE DISASSEMBLING ..................... 17
❱❘ Gearbox draining ...................................... 17
❱❘ Front sprocket removal ............................. 17
❱❘ Top-end removal ....................................... 17
❱❘ Reeds valve removal ................................ 19
❱❘
Right side disassembling ................... 19
❱❘ Clutch cover removal ................................ 19
❱❘ Coolant pump disassembling.................... 20
❱❘
Clutch and primary drive removal ............. 21
❱❘ Kickstarter shaft removal .......................... 24
❱❘ Shifting mechanism removal .................... 24
❱❘
Left side disassembling. .................... 25
❱❘ Ignition removal. ....................................... 25
❱❘
Crankcase splitting ............................. 26
❱❘ Gearbox removal ...................................... 27
•
❱❘ Disassemble the selector fork- drum
assembly ...................................................... 28
ENGINE PARTS CHECK ......................... 30
❱❘ Crankshaft removal................................... 30
❱❘ Crankshaft width measure ........................ 31
❱❘ Big-end radial play .................................... 31
❱❘ Axial play of the big end ........................... 31
❱❘ Crankshaft runout check ........................... 32
❱❘ Piston ........................................................ 33
❱❘ End gap .................................................... 33
❱❘ Wrist pin check ......................................... 33
❱❘ Cylinder – piston wear condition ............... 34
❱❘ Reeds valve, intake boot .......................... 34
❱❘ Clutch ........................................................ 35
❱❘ Discs check ............................................... 35
❱❘ Gearbox shafts ......................................... 36
ENGINE ASSEMBLING ....................... 37
❱❘ Gearbox assembling. ................................ 37
❱❘
Accoupling the crankcases................ 39
❱❘
Left hand side assembling ................. 39
❱❘ Fitting the ignition ...................................... 39
❱❘
Right-hand side assembling .............. 40
❱❘Clutch assembling ..................................... 40
•
Fit the clutch basket and the clutch hub.
42
Using the tool ............................................... 42
❱❘
Top-end assembling ........................... 45
❱❘Piston fitting ............................................... 45
❱❘ Squish check ............................................ 47
❱❘ Reed valve and intake boot ...................... 48
❱❘ Gearbox output sprocket .......................... 48
TIGHTENING TORQUES .............................. 49
To Next Page
Loading...
Need help?
General
