A Loosely assemble the left-hand sub-frame...

B ... and sub-frame nuts and bolts

Engine, clutch and transmission 2»9

Position the front bolt spacers on each side (R, T, V, W, X, Y only)

5.35a Tighten the lower rear mounting bolt...

5.35b... followed by the upper rear mounting bolt...

5.35c .. . the lower sub-frame bolts...

5.35d ... theupper sub-frame bolts .

E ... and the front mounting bolt

bolt. Next tighten the upper rear mounting bolt, the four sub-frame bolts, and on SW, SX and SY models the bolts securing the frame crossmember to the frame. Finally tighten the front mounting bolt (see illustrations). 36The remainder of the installation procedure is the reverse of removal, noting the following points.

a) Make sure all wires, cables and hoses are correctly routed and connected, and secured by the relevant clips or ties. bj Adjust the throttle and clutch cable freeplay (see Chapter 1).

c) Adjust the drive chain (see Chapter 1).

d) Refill the engine with oil and coolant (see Chapter 1).

e) Before riding the bike, start the engine and check that there are no signs of coolant/oil leakage.

6 Engine disassembly and reassembly -general information

Disassembly

1 Before disassembling the engine, the external surfaces of the unit should be thoroughly cleaned and degreased. This will prevent contamination of the engine internals, and will also make working a lot easier and cleaner. A high flash-point solvent, such as paraffin (kerosene) can be used, or better still, a proprietary engine degreaser such as Gunk. Use old paintbrushes and toothbrushes to

work the solvent into the various recesses of the engine casings. Take care to exclude solvent or water from the electrical components and inlet and exhaust ports.

Warning: The use of petrol (gasoline)as a cleaning agent should be avoided because of the risk of fire.

2 When clean and dry, arrange the unit on the workbench, leaving suitable clear area for working. Gather a selection of small containers and plastic bags so that parts can be grouped together in an easily identifiable manner. Some paper and a pen should be on hand so that notes can be made and labels attached where necessary. A supply of clean rag is also required.

3 Before commencing work, read through the appropriate section so that some idea of the necessary procedure can be gained. When removing components it should be noted that great force is seldom required, unless specified. In many cases, a component's reluctance to be removed is indicative of an incorrect approach or removal method - if in any doubt, re-check with the text.

4 When disassembling the engine, keep 'mated' parts together (including gears, pistons, connecting rods, valves, etc. that have been in contact with each other during engine operation). These 'mated' parts must be reused or renewed as an assembly.

5 A complete engine/transmission disassembly should be done in the following general order with reference to the appropriate Sections.

Remove the valve cover

Remove the camchain tensioner

Remove the camshafts

Remove the cylinder head

Remove the starter motor (see Chapter 9)

Remove the alternator (see Chapter 9)

Remove the starter clutch

Remove the timing rotor, primary drive gear

and balancer gear Remove the clutch Remove the oil pump Remove the water pump (see Chapter 3) Remove the gearchange mechanism

external components o

Remove the oil sump Separate the crankcase halves Remove the connecting rods and pistons Remove the crankshaft Remove the balancer shaft Remove the camchain and guides Remove the transmission shafts Remove the selector drum and forks

Reassembly

6Reassembly is accomplished by reversing the general disassembly sequence.

7 Valve cover-

removal and installation

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Note:This procedure can be carried out with the engine in the frame. If the engine has been removed, ignore the steps that do not apply.

2*10 Engine, clutch and transmission

Date: 2016-01-14; view: 788