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."
GEAR LASH MEASUREMENT
NOTE:
The middle gear lash can be checked only when the gears are installed in the crankcase.
1. Attach:
• Middle Drive Pinion Holder (90890-04051) 1 .
MIDDLE GEAR SERVICE
1. Refer to engine removal. Reverse those removal steps that apply.
2. Tighten engine mounting bolts
Engine Mounting Bolt: Front 1: 42 Nm (4.2 m-kg, 30 ft-lb)
Rear 2 : 90 Nm (9.0 m-kg, 65 ft-lb)
Down Tube 3 , Bracket 4 : 33 Nm (3.3 m-kg, 24 ft-lb)
RADIATOR PIPES, CARBURETOR JOINT, AND OIL DELIVERY PIPE
1. Install:
• Union bolt with copper washer 1
• Cylinder head side cover 2
Oil Delivery Pipe: 21 Nm (2.1 m-kg, 15 ft-lb)
CYLINDER HEAD
1 Check bolt
2 Dowel pin
3 Camshaft case gasket
4 Valve guide
5 O-ring
6 Camshaft case
7 Cylinder head
8 Oil pipe
[A] Be sure the "UP" mark faces upward.
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)
MIDDLE GEAR
1. Install:
• Bearing retainers 1
• TORX screws (New)
• Oil level maintaining plug
Bearing Retainer: 25 Nm (2.5 m-kg, 18 ft-lb)
OIL PUMP AND OIL PAN
1 Chain cover
2 Oil pump sprocket
3 Oil pump drive sprocket
4 Oil pump cover
5 Inner rotor
6 Spring
7 Relief valve
8 Shaft
9 Dowel pin
10 Outer rotor
11 Dowel pin
12 O-ring
UPPER CRANKCASE
