Immerse the air cleaner element in the cleaning solvent and wash it. Install new O-rings to the valve inspection caps. Slide the adjuster 2 until the cable play at the reverse lock release knob A reaches 1 2 mm 0. Disconnect the rear brake cable 3 and remove the handlebar switch 4. Loosen the cylinder base nuts M6 2.
Remove the dowel pins and gasket. If the runout exceeds the service limit, replace the valve with a new one. Install the brake pedal as its slit matches with the punched mark on the shaft. Neutral switch 30ß lead wire 10ß Rear brake lamp switch harness Carburetor. Remove the right front fender bracket F. If any damages are found, replace the dust seal with a new one. Valve clearance out of adjustment.
If the conrod small end inside diameter exceeds the service limit, replace the conrod with a new one. Install the clutch sleeve hub assembly into the primary driven gear assembly. If not, set the clutch release outer guide in suitable position. Remove the throttle stop screw 5. Gearshift lever Fix the clutch release outer guide by tightening the clutch release outer guide nuts 1.
Install the new O-ring A onto the oil filter fitting boss of the clutch cover. Make sure all the tires are inflated to the standard pressure. Step 1 1 Check accessories which use excessive amounts of electricity. If the resistance is not specified value, replace the stator coil with a new one. If any damages are found, replace the dust seals with new ones. Replace the removed O-ring with a new one to prevent leakage of fuel. Step 2 1 Check the battery for current leaks.
If the pinion gear is damaged, inspect the ring gear also. Remove the rear upper engine mounting nut, bolts and bracket E. Major lubrication points are indicated below. Do not reuse the dust seal and piston seal to prevent fluid leakage. They are specifically written for the do it yourself as well as the experienced mechanic.
Weak- ened spring result in reduced engine power output, and often account for the chattering noise coming from the valve mecha- nism. Install the gearshift forks and shafts as shown. Remove the secondary drive bevel gear and driveshaft assembly, countershaft assembly. If the valve stem outside diameter is within specification, but the valve stem deflection is not, replace the valve guide with a new one. They bear the following identification mark.
Remove the screws that connect the front fender with the head light. Install the oil pump drive gear. Inspect the pinion gear for wear or damage. After a snap ring has been removed from a shaft, it should be discarded and a new snap ring must be installed. Check that the fuse is not blown and the battery is fully-charged before diagnosing. Also, check that the generator core is insulated. If each drive plate is not within the standard range, replace it with a new one.
Remove the drum cover bolts. Check the generator, and regu- quickly. Remove the clutch release plate 1 and springs. Drive out the bearing from the other side with the special tool. Turn the adjuster 2 in or out to obtain the correct play. Replace the removed O-ring with a new one.