C. Middle Gear Servicing
1. Disassembly
Refer to page 39 for disassembly.
2. Inspection
Refer to page 52 for inspection.
3. Gear lash check
NOTE:
The middle gear lash can be checked only when the gears are installed in the crankcase.
D. Remounting Engine
Refer to page 30 for engine removal. Reverse the applicable removal steps.
CAUTION:
Always use new bolts in the drive shaft coupling.
2. Install and tighten the engine mounting bolts.
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Engine mounting bolt torque: |
11. Pistons and Cylinder a. Install the pistons on the rods. The arrow on the piston must point to the front of the engine.
NOTE:
Before installing the piston pin clips, cover the crankcase with a clean rag so you will not accidentally drop the circlip into the crankcase.
Always install new piston pin circlips.
6. Middle gear (installation only, refer to page 67 for the middle gear adjustment)
a. Install the middle drive gear assembly with the proper size of shim(s) and secure it with the bearing retainers and new "TORX" screws.
Tightening torque: 2.5 m-kg (18 ft-lb)
1. Shims
8. A.C. Generator
a. Install the rotor onto the shaft and tighten the bolt using the rotor holding tool (special tool) as shown.
1. Rotor holding tool
Tightening torque: 5.5 m-kg (39.8 ft-lb)
b. Install the stator coil assembly onto the crankcase and align the grooves on the stator core with the bolt holes on the crankcase.
2. Lower crankcase
a. Install the shift cam and secure it with the guide pin. Install the stopper plate and bolt and tighten securely.
b. Install the neutral switch.
c. Install the transmission drive axle assembly into the crankcase.
P. Middle Gear
1. Damper disassembly
NOTE:
Disassembly of the middle gear damper requires the damper compressor (special tool) and a hydraulic press.
a. Place the middle drive shaft in a press with the damper compressor (special tool) in place as shown.
I. Crankshaft
1. Crankshaft run-out
Support the crankshaft at both ends on V-blocks. Measure the amount of crankshaft run-out on the main bearing journals with a dial gauge while rotating crankshaft.
Run-out limit: 0.040 mm (0.0016 in)
If run-out exceeds limit, replace crankshaft.
2. Inspection of bearings
L. Lower Crankcase
1. Remove the dowel pin and "O-ring".
2. Remove the shift fork guide bar and shift forks. The shift forks are identified by numbers cast on their sides.
3. Remove the bolt securing the shift cam locating pin and remove the stopper plate and locating pin.
4. Remove the neutral switch.
D. Valve Spring and Lifters
1. Checking the valve springs
a. This engine uses two springs of different sizes to prevent valve float or surging. The valve spring specifications show the basic value characteristics.