SHIFTER AND MIDDLE GEAR
1. Remove:
• Crankcase cover (Left) 1
• Gasket
• Dowel pin 2
• Shift shaft 3
• Shift lever 4
• Oil level maintaining plug 5
2. Remove:
CLUTCH
1. Remove:
• Water pump drive sprocket cover 1
• Water pump drive sprocket 2
Note:
Water pump drive sprocket bolts 3 is locked with LOCTITE®.
• Spacer
PISTON AND CAM CHAIN GUIDE
Mark each piston so it can be reinstalled in the appropriate cylinder.
1. Remove:
• Piston pin clips 1
• Piston pins 2
RADIATOR PIPES, CARBURETOR JOINT, AND OIL DELIVERY PIPE
1. Remove:
• Radiator pipe 1
• Cover (Right) 2
2. Drain the coolant (in the cylinder) by removing drain bolts 3
PREPARATION FOR REMOVAL
1. Remove all dirt, mud, dust, and foreign material before removal and disassembly.
2. Use proper tools and cleaning equipment. Refer to CHAPTER 1, "SPECIAL TOOLS."
NOTE: It is not necessary to remove the engine in order to remove the following components:
• Piston
• Clutch
• Carburetor
• Oil pump
• Water pump
HEADLIGHT
Headlight Bulb Replacement
1. Remove securing screws (1) from light unit assembly/headlight body.
2. Disconnect the headlight lens unit leads
3. Remove the light unit assembly
Front Wheel Bearings
1. Raise the front end of the motorcycle, and spin the wheel by hand. Touch the axle or front fork white spinning the wheel. Replace the bearings if any vibration is detected.
Note: It may be necessary to retract the brake pads from the disk in order to freely rotate the wheel.