Remove air cut-off valve cover, spring and valve. Final shaft Counter shaft Shift drum. Place the openings of piston ring as diagram shown. Remove the battery clamp, and then remove battery. Remove water pump cover 4 bolts. Drive face boss Movable drive face Drive face boss. Balance shaft Remove crankshaft from right crankcase.
Reverse shaft Drive shaft Install counter shaft, reverse shaft and final shaft onto gear box. Loosen rear cushion under bolt nut, and remove rear cushion under bolt. Old valve seat width 60° Use 45° cutter to grind the valve seat to specified width. If air-flow is no restricting, replace carburetor assembly. Loosen 2 screws and 2 bolts Remove the tank cover Check all lines, and replace it when they are deterioration, damage or leaking Fuel hose Warning Gasoline is a low ignition material so any kind of fire is strictly prohibited as dealing it.
Thermo-sensor wire Remove gear change lever 1 bolt. Remove front fender and the footrest refer chapter 13. Choke cable Vacuum pipe Fuel pipe Disconnect the fuel hose. Caution Do not damage contact surface of the gasket. Coolant hose Cover the holes of crankcase and cam chain with a piece of cloth. Driven sprocket holder Install rear brake disk bracket and disk.
Tighten 11 bolts on the left crankcase. Remove drain bolt and drain gear oil out. Clean residues and foreign materials on cylinder head matching surface. Hang the thermo unit in an oil heater, heat the oil and measure the resistance at each temperature. Body Construction Characteristics the following measures have been implemented in order to provide maximum corrosion prevention and protection: The use of galvannealed coatings throughout the body structure; Ecoat is used on the complete body in all instances; Body sealing; Stone-chipping resistant primer application; Underbody corrosion prevention. Fuel level plate Inspection Check float valve and valve seat for damage, blocking. Drain bolt Remove the thermo-sensor wire, by-pass pipe and By-pass pipe Outlet hose coolant outlet hose.
Inner bearing puller Special tool: Inner bearing puller Remove oil seal from gear box cover and discard the seal Install new bearing and bearing driver into gear Universal box cover outer side. Steering shaft nut Remove the cotter pin steering shaft, and below remove steering shaft nut and washer. Unit Green White Yellow Blue Fuse 15A Ignition coil Main fuse Spark plug Battery Main switch Pulse generator C. Install the impeller onto the water pump shaft and Water pump rotor tighten. Remove 2 bolts, and then remove rear brake caliper.
. Install wheel hub and brake disk on to knuckle. Service Limit: Top ring: 0. When maintenance brake system, will be supposed to paint the surface or the rubber parts catches up by the rags. Replace the piston if its measured value exceeds allowable limit. Otherwise, the cylinder head may be deformed as heating it.
Disconnect two 3 pin couplers of the regulator rectifier. Service Limit: Replace when it is less than 12. Caution Do not damage the matching surfaces of cylinder and cylinder head. Tighten the sprocket mounting bolts. Cotter pin Bend out the steering shaft holder nut fixed plate. Cylinder Head Reassembly Lubricate Valve spring retainer valve stem with engine oil, and then insert the Valve stem seal. Check the following connectors as indicated in the table at the harness side.
Water pump oil seal Special tools: driver inner Water pump oil seal driver inner Install a new outside bearing to the right Water pump bearing crankcase cover. Check if bearings can be turned in smooth and silent, and also check if bearing outer ring is mounted on bearing seat. Caution Do not press the compressor too much. Caution The movable drive face surface has to be free of grease. Inspection Inspect the tie-rod for damage or bending. Turn the socket bolt clockwise, and then remove 3 bolts speedometer gear box.