CRANKSHAFT AND CONNECTING ROD
Crankshaft Runout
1. Place both ends of crankshaft on V-blocks.
2. Rotate Crankshaft
3. Measure the crankshaft runout at main journal bearings. Use a Dial Gauge (90890-03097).
REMOVAL
Middle Drive Gear
NOTE:
Middle drive gear and its shims can be removed without separating the engine.
1. Remove the clutch cover. Refer to "ENGINE DISASSEMBLY."
PISTON AND CYLINDER
1 Cylinder head gasket
2 Dowel pin
3 Drain bolt
4 Oil delivery pipe
5 O-ring
6 Cylinder base gasket
7 Piston ring
8 Piston pin clip
9 Piston pin
10 Copper washer
1. Install:
• Piston rings (onto the pistons)
STARTER MOTOR
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. Inspect:
• Clutch housing dogs 1
Cracks/Pitting (edges): Moderate -> Deburr.
Severe -> Replace clutch housing.
2. Inspect
• Clutch housing bearing 2
• Spacer 3
1. Measure the valve stem clearance
Use a bore gauge 3 to determine the valve guide inside diameter.
Valve Guide Inside Diameter Limit: 5.05 mm (0.199 in)
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
UPPER CRANKCASE
CYLINDER
1. Inspect the cylinder walls for vertical scratches and Rebore or Replace cylinder as required.
2. Measure the cylinder inside diameter.
