ENGINE

CONTENTS
REMOVABLE ENGINE PARTS WITH ENGINE IN PLACE 3-1

ENGINE REMOVAL AND REMOUNTING 3-2

CYLINDER HEAD AND VALVE 3-7

CYLINDER AND PISTON 3-17

CLUTCH 3-21

OIL PUMP 3-26

GEAR SHIFTING MECHANISM 3-27

GENERATOR AND STARTER CLUTCH 3-28 3

CRANKSHAFT, TRANSMISSION AND KICK STARTER DEVICE 3-31
 ENGINE

REMOVING ENGINE PARTS WITH ENGINE IN PLACE

UPPER SIDE OF ENGINE

Starter motor 3-7
Cam chain tensioner 3-7
Cam sprocket 3-8
Cam shaft 3-8
Valve rocker arm 3-9

RIGHT SIDE OF ENGINE

Kick starter lever 3-21

Clutch cover 3-21
Oil filter 3-21
Clutch 3-22
Oil pump 3-26
Gear shifting lever 3-27

LEFT SIDE OF ENGINE

Engine sprocket cover 3-28

Starter motor reduction gear 3-28
Generator cover 3-28
Starter gear idle gear 3-28
Generator rotor 3-29
Starter clutch 3-29
Generator stator 3-29
Trigger coil 3-29

3-1
 ENGINE

ENGINE REMOVAL AND REASSEMBLY

ENGINE REMOVAL
Before taking the engine out of the chassis, wash the engine
with a steam cleaner. The procedure of engine removal is
sequentially explained in the following steps:

Remove the left and right side cover.

Open the saddle lock, take off the saddle.

Remove the battery - lead wire 3 .

Turn the fuel switch to ”●” position .

Remove the fuel hose 2 .

Disconnect the tilt stop valve hose 5 .

Disconnect the fuel level gauge coupler 6 .
Remove the fuel tank bolts, take off the fuel tank 7 .

3-2
 ENGINE

● Loosen the clutch cable lock nut and adjust nut, disconnect
the clutch cable 8 from clutch rock arm.

Loosen the generator wire clamp, take off the PVC bag 9
Disconnect the gear switch coupler 10 and generator
coupler 11 .

Loosen the choke cable mounting screw, take off the choke
cable 12 .
Remove the balancer pipe 13 .
Remove the overflow pipe 14 .

Disconnect the vacuum hose 15 .

Disconnect the throttle cable and carburetor piston
assembly 16 .
Remove the breather hose 17 .
Remove the carburetor intake pipe nut and intake pipe bolt
18 .

Loosen the carburetor clamp screws 19 , remove the

carburetor 20 and intake hose .

3-3
 ENGINE

Loosen the rear axle nut 22, lock nut and chain adjuster bolt

Remove the gear shifting lever .

Remove the crankcase breather hose 26 , starter motor wire 27

and engine ground wire 28 .
Disconnect the spark plug cap 29 .

Remove the rear sprocket cover 29 .

● Disconnect the drive chain 30 by removing the clip.

3-4
 ENGINE

Disconnect the 2nd air intake hose 31 .

Remove the exhaust pipe bolts.

● Remove the exhaust pipe and muffler mounting bolts and

nuts, take off the muffler 32 .

● Remove the engine rear mounting nuts 33 .

● Remove the right front footrest mounting bolt, remove the

right front footrest 34 .
● Remove the engine upper mounting nuts 35.

● Remove the engine front hanging mounting nut 36 , and

engine front mounting nut 37 .
● Pull out the mounting bolts, remove the front hanging
bracket 38 and engine.

3-5
 ENGINE

ENGINE REMOUNTING
The engine can be mounted in the reverse order of removal.
Pay attention to the following points:
● Temporarily fasten the engine mounting bracket before
inserting the engine mounting bolts.

The engine mounting nuts are self-lock nuts. Once the

nut has been removed, it is no longer of any use.

Tightening torque for engine mounting bolts

Engine front mounting nut A : 37~45 N•m

Engine front hanging nut B : 23~28 N•m
Engine upper mounting nut C : 28~34 N•m
Engine rear mounting nut D : 45~55 N•m
Right footrest mounting bolt E : 40-60 N•m
Muffler bolt F : 13-15 N•m
Rear footrest nut G : 55-65 N•m

D E
F

Install the drive chain clip with the opening as shown in the
right illustration.

After remounting the engine, add the engine oil to the

engine. (Refer to page 2-8).
Check the engine oil level. (Refer to page 2-8).

After remounting the engine, following adjustments are

necessary.
* Throttle cable (page 2-10)
* Clutch cable (page 2-9)
* Idling speed (page 2-9)
* Drive chain (page 2-11)
3-6
 ENGINE

CYLINDER HEAD AND VALVE

REMOVAL
● Drain the engine oil, take off the engine. (Refer to page 3-
2)

● Remove the starter motor mounting bolts, take off the

starter motor 10
1.

Remove the camshaft chain tensioner 2 .

Remove the generator cover cap 3 and inspection plug 4

.

Remove the valve inspection cover 5 .

3-7
 ENGINE

● Remove the cylinder head left cover 6 .

● Bring the piston to top dead center.

When removing the cylinder head cover, piston must be

at top dead center on compression stroke.

Match the mark A on the camshaft sprocket with the B

B
mark on the cylinder head.
Remove the camshaft sprocket mounting bolt 7 , take off
the camshaft sprocket.
A

Do not drop the sprocket, cam chain and bolts into the
crankcase.

Remove the cylinder head mounting nut 8 and bolt 9,

take off the cylinder head and gasket.

CAUTION

Remove the bolt 9 first.

CAUTION

If it is difficult to remove the cylinder head, gently pry it

off while tapping the finless portion of the cylinder
head with a plastic hammer. Be careful not to brake the
fins.

Remove the cylinder head gasket 10 and dowel pins.

3-8
 ENGINE

DISASSEMBLY
Remove the cam chain tension guide rod 10
1.

Remove the rocker arm shaft block plate 2 .

Remove the camshaft 3 .

Pull out the rocker arm shaft 4 , take off the rocker arm
5 and spring 6 .

3-9
 ENGINE

● Remove the valve cotters with the special tool.

11F14-018 : Valve remover and installer

Remove the valve spring retainer, inner spring and outer

spring.
Pull out the valve from the other side.

● Remove the oil seal.

Removed oil seal should be replaced with a new one.

Take off the spring lower retainer.

INSPECTION
ROCKER ARM SHAFT
Measure the diameter of rocker arm shaft.

Rocker arm shaft OD (IN.& EX.)：

Standard：11.986-11.994 mm

09900-20205 : Micrometer (0-25 mm)

ROCKER ARM
Check the inside diameter of the valve rocker arm and wear
of the camshaft contacting surface.

Rocker arm ID (IN.& EX.)：

Standard: 12.0-12.018 mm
09900-20605 : Caliper gauge

3-10
 ENGINE

VALVE SPRING
Measure the valve spring free length.

Valve spring free length (IN and EX):

Limit (IN) : 37.44 mm
(EX): 40.13 mm

09900-20101: Vernier calipers (150 mm)

CAMSHAFT
The camshaft should be checked for runout and also for
wear of cams and journals if the engine has been noted
to produce abnormal noise or vibration or a lack of output H
power.
Worn-down cams are often the cause of mistimed valve
operation resulting in reduced output power. The limit of cam
wear is specified for both intake and exhaust cams in terms of
cam height H , which is to be measured with a micrometer.
Replace camshafts if found it worn down to the limit.

CAM HEIGHT

CAM HEIGHTH :
Limit (IN)：31.036 mm
EX(EX)：30.941 mm

09900-20202: Micrometer (25-50mm)

CYLINDER HEAD
Check the spark plug hole and valve of combustion
chamber part for crack.
Check the gasketed surface of the cylinder head for
distortion with a straightedge and thickness gauge.

Cylinder head distortion:

Limit: 0.05 mm

09900-20803:Thickness gauge

3-11
 ENGINE

Measure the thickness 10

1 , and if the thickness is found to
have been reduced to the limit, replace the valve.

Valve face thickness: Limit: 0.5 mm

Visually inspect each valve for wear of its seating face.

Replace any valve with an abnormally worn face.

● Support the valve with “V” blocks, as shown, and check its
runout with a dial gauge. The valve must be replaced if the
runout exceeds the limit.
Valve stem runout:
Limit: 0.05 mm

09900-20606: Dial gauge (1/100 mm)

09900-20701: Magnetic stand
09900-21304: V-block ( 100 mm)

Place the dial gauge at right angles to the valve head,

and measure the valve head radial runout. If it measures
more the limit, replace the valve .
Valve head radial runout:
Limit: 0.03 mm

09900-20606: Dial gauge (1/100 mm)

09900-20701: Magnetic stand
09900-21304: V-block ( 100 mm)

VALVE STEM
Check the valve stem for bending or abnormal wear.
Measure the valve stem O.D.

Valve stem O.D.:

Standard (IN): 4.975-4.99 mm
(EX): 4.955-4.97 mm

09900-20205 : Micrometer (0~25 mm)

OIL SEAL
● Oil each seal, and drive them into position.

Always use new oil seal.

3-12
 ENGINE

VALVE SEAT WIDTH

Coat the valve seat with prussian blue uniformly. Fit the valve and tap
the coated seat with the valve face in a rotating manner, in order to
obtain a clear impression of the seating contact. In this operation, use
the valve lapper to hold the valve head.
The ring-like dye impression left on the valve face must be
continuous-without any break. In addition, the width of the dye ring,
which is the visualized seat “width”, must be within the specification.
09916-10911 : Valve lapper set

Valve seat width W : Standard:

IN:1.0-1.2 mm
EX:1.1-1.3 mm
If either requirement is not met, correct the seat by servicing it as
follows.
VALVE SEAT SERVICING
● The valve seats 10
1 for both intake and exhaust valves are
angles to present 3 bevels. The valve seat contact surface
is 45°.

INTAKE 排 气门 进气门
ANGLE 30°,45° 30°,45°
WIDTH 1.0-1.2 mm 1.1-1.3 mm
DIAMETER 29.0 mm 25.0 mm
VALVE GUIDE I.D. 5 . 0 0 0 - 5 . 012 mm

After the desired seat position and width is achieved, use

the 45 o cutter very lightly to clean up any burrs caused by
the previous cutting operations. DO NOT use lapping
compound after the final cut is made. The finished valve
seat should have a velvety smooth finish and not a highly
polished or shiny finish. This will provide a soft surface for
the final seating of the valve which will occur during the first
few seconds of engine operation.

CAUTION

After servicing the valve seats, be sure to check the

valve clearance after the cylinder head has been
reinstalled.

Clean and assemble the head and valve components. Fill the
intake and exhaust ports with gasoline to check for leaks. if any
leaks occur, inspect the valve seat and face for burrs of other
things that could prevent the valve from sealing.

WARNING

Always use extreme caution when handling gasoline.

3-13
 ENGINE

CYLINDER HEAD REASSEMBLY

● Clean the cylinder head with the detergent, clean all the oil
passages with compressed air.
● Clean each valve with Moly paste.
● Insert the valves into valve guide and Install the gasket,
spring, valve spring retainer.

99000-25140 : Moly paste

CAUTION

Install valve springs, making sure that the close-

pitch end of each spring goes in first to rest on the
head.
Turn the valve slowly while installing the valve oil seal

● Install the valve cotters with the special tool.

11F14-018 : Valve remover

3-14
 ENGINE

Oil the rocker arm.

Install the rocker arm, spring and rocker arm shaft to the
cylinder head.

● Apply a small quantity of moly paste to the tip of cam shaft and
journal, install the cam shaft to the cylinder head.
● Install the rocker arm block plate, and tighten the rocker arm shaft block
plate bolt.

99000-25140 : Moly paste

Apply the Bond " 1207B" to the cam chain tensioner, then
install the the cam chian tensioner.

99000-31140 : Bond “1207B”

REASSEMBLY
Reassemble the cylinder head in the reverse order of removal.
Pay attention to the following points:

Clean up the remaining gasket on the cylinder head

surface.

Do not let the dirt and dust get into the engine.

Install the guide rod, dowel pins and cylinder head gasket 10
1.

3-15
 ENGINE

Install the 4 cap nuts and gaskets, tighten the nuts to the
specified torque.
Cylinder head cover nut: 25-35 N•m

● Install the camshaft, cam sprocket and cam chain.

B

Bring the piston to TDC before installing the camshaft

and sprocket. Match the mark A on the sprocket with the A

mark B on the cylinder head.

Apply the thread lock to the bolt and tighten.

99000-32050 : Thread lock "1303"

● Install the cylinder head left cover and gasket.

Replace the gasket with a new one.

● Inspect the valve timing inspection hole cover and O-ring.

Replace the O-ring with a new one.

● Install the cam chain tensioner.

● Inspect the valve clearance. (Refer to page 2-5)

3-16
 ENGINE

CYLINDER AND PISTON

CYLINDER REMOVAL AND DISASSEMBLY
Remove the cylinder head (Refer to page 3-7).
Remove the gasket, dowel pin and guide rod.
Remove the cylinder.

CYLINDER INSPECTION
Remove the gasket material on the fitting surface of cylinder.
Check the gasketed surface of the cylinder for distortion
with a straightedge and thickness gauge.

Cylinder distortion:
Limit: 0.05 mm
09900-20803 : Thickness gauge

Check the cylinder bore for wear or damage.

Measure the cylinder bore diameter at six places. If any
one of the measurements exceeds the limit, overhaul the
cylinder and replace the piston with an oversize, or replace
the cylinder.
Cylinder bore diameter:
Limit: 57.43 mm

09900-20508 : Cylinder gauge set

PISTON REMOVAL AND INSPECTION

REMOVAL
CAUTION
Place a clean rag over the cylinder base to prevent
piston pin circlip from dropping into the crankcase.
● Remove the piston pin circlip.
● Remove the piston pin and piston with the special tool.

09910-34510 : Piston pin remover

CAUTION
Hold the piston when pulling out the piston pin to prevent
the damage to the big end of conrod bearing.

● Removing the piston rings one by one by expanding the

gap symmetrically.
CAUTION
Do not expand the piston ring excessively since it is apt
to be broken down.
When installing the piston ring, be careful not to damage
the piston.
3-17
 ENGINE

Decarbonize the piston.

CAUTION

Using a soft-metal scrapper or discarded piston ring to

decarbon the ring grooves of the piston. Do not use the
steel brush or the piston will be scratched .

INSPECTION
Fit the rings on the piston with marked side faces upward.
Using a thickness gauge, measure the side clearance of the
1st and 2nd rings.If any of the clearances exceeds the limit,
replace both piston and piston rings.

Piston ring-groove clearance:

1st: 0.18 mm
2nd: 0.15 mm

09900-20803 : Thickness gauge

Using a micrometer, measure the piston outside diameter

at the place 7mm from the skirt end as shown in Fig.
7mm
Piston Diameter: Limit: 56.35 mm
09900-20203 : Micrometer (50~75 mm)

Measure the piston pin bore inside diameter.

Piston pin bore: Limit: 14.03 mm

09900-20605 : Caliper gauge

Measure the piston pin O.D.

Piston pin O.D. : Limit: 13.980 mm

09900-20205 : Micrometer (0~25 mm)

3-18
 ENGINE

● Measure the piston pin bore inside diameter.

Piston pin bore: Limit: 14.04 mm

09900-20605 : Caliper gauge

Fit the ring in the cylinder, and measure each ring end gap
using a thickness gauge.

Piston ring end gap:

(1st)：0.50 mm
(2nd)：0.50 mm

09900-20803 : Thickness gauge

Make sure to fit the piston ring in the cylinder evenly

with the piston head.

REASSEMBLY
Install the piston and cylinder in the reverse order of
removal. Pay attention to the following points:
● Clean the top, skirt or groove of the piston.

CAUTION
Hold each piston ring with the piston rings properly
spaced and insert them into the cylinder.
Check to insure that piston rings are properly inserted
in the the cylinder skirt.

● Be sure to bring the marked side to the top when fitting the
piston rings to the piston.
12 0°

12
0° 0°
Install the piston rings in the order of oil ring, 2nd ring 12

and 1st ring. Do not align the gap of oil ring with
expander ring.
The gaps of two piston rings should be staggered at 120°.

Install the piston rings in the order of oil ring, 2nd ring
and 1st ring. Do not align the gap of oil ring with the gap
of expander ring.
● Piston ring should turn smoothly in the piston groove
after assembly.
3-19
 ENGINE

● Oil the piston pin outer surface.

p ● Place a clean rag over the cylinder base to prevent piston pin
circlip from dropping into crankcase, and then fit the piston pin
h circlip with long-nose pliers.

Replace with a new piston pin circlip to prevent circlip

slipping from position.
End gap of the circlip should not be aligned with the
cutaway in the piston pin bore.

When fitting the piston, turn mark “IN” on the piston head to
the exhaust side.

Before mounting the cylinder, oil the big end and small end of
the conrod and also the sliding surface of the piston
Fit the dowel pins 101 to the crankcase and then fit the
gasket.

99000-31110 : Bond "1215"

Hold the piston rings in proper position, oil the piston and insert it
into the cylinder. Check to insure that the piston rings are properly
inserted into the cylinder skirt.

CAUTION

When mounting the cylinder, after attaching camshaft

drive chain 2 , keep the camshaft drive chain taut, The
camsahft drive chain must not be caught between cam
drive chain sprocket and crankcase when crankshaft is
rotated.

There is a holder for the bottom end of the cam

chain guide cast in the crankcase. Be sure that
the guide is inserted properly or binding of the cam
chain and guide may result.

Install the cylinder head. (Refer ‘ to page 3-15)

3-20
 ENGINE

CLUTCH
REMOVAL
Drain the engine oil.
1.
Loosen the clutch adjuster bolt, take off the cable 10

Remove the kick starter lever 2 .

Remove the oil level gauge 3 .

Remove the clutch cover screws diagonally, take off the clutch cover 4

Remove the gasket and dowel pins.

Remove the oil filter rotor cover 5 .
Remove the clutch push rod 6 and bearing 7 .

CAUTION
Always use new gasket.

Hold the crankshaft with the special tool, remove the oil
filter rotor lock nut.

11F14-030 : Gear stopper

11F14-011 : 4 claws sleeve

3-21
 ENGINE

● Remove the gasket and oil filter rotor 8 .

● Hold the clutch with the special tool, remove the cutch hub

09930-40113 : Sprocket holder

11F14-011 : 4 claws sleeve

Remove the washer and clutch driven hub assembly 9 .

Remove the clutch washer and primary driven gear

assembly 10 .

Disassemble the clutch driven hub, take off the clutch push
set, spring, clutch drive and driven plates.

3-22
 ENGINE

INSPECTION
Measure the thickness and claw width of each drive
plate with vernier calipers. Replace drive plates found to
have worn down to the limit.

09900-20103 : Vernier calipers

Checking thickness
Drive plate thickness:
Limit: 2.65 mm

Claw width:
Limit: 15.5 mm

Checking claw width

Measure each driven plate for distortion with a thickness

gauge. Replace driven plates which exceed the limit.

09900-20803 : Thickness gauge

Driven plate distortion: Service limit: 0.1 mm

CAUTION
Replace the drive and driven plates as a set if exceed Checking distortion
the limit.

Measure the clutch spring free length.

Clutch spring free length:
Limit: 36.2 mm

09900-20103 : Vernier calipers

CAUTION
If any one of springs is not within the limit, replace all
the springs at a time.

Inspect the release bearing for any abnormality, particularly

cracks, to decide whether it can be reused or should be
replaced.

3-23
 ENGINE

Inspect the primary driven gear for damage or wear caused

by the clutch plates, if necessary, replace it with a new one.

● Inspect the clutch sleeve hub for damage or wear caused

by the clutch driven plates. If necessary, replace it with a
new one.

REASSEMBLY
● Apply engine oil to the clutch drive and driven plates,
reassemble the clutch driven hub assembly, and install the
clutch spring, push set and bolts.

The top and bottom clutch drive plates have a different

color with other three middle clutch plates. When
installing the clutch drive plates, fit the top one to the
shallow gap of primary driven gear .

REASSEMBLY
Reassemble the clutch in the reverse order of removal, pay
attention to the following points:
Hold the primary drive gear with the special tool, tighten
the clutch sleeve hub nut the specified torque.

11F14-030 : Gear stopper

11F14-011 : 4 claws sleeve
Clutch lock nut: 40-45 N•m

● Install the oil filter rotor and washer, tighten the filter rotor
lock nut to the specified torque.

09930-40113 : Sprocket holder

11F14-011 : 4 claws sleeve

Oil filter rotor lock nut: 40-45 N•m

3-24
 ENGINE

● Install the oil filter rotor cover, apply the Thread lock
" 1342" to the screws.
99000-32050: Thread lock”1342"

Do not use the old gasket to prevent oil leakage.

Install a new gasket and dowel pins.

Do not use the old gasket to prevent oil leakage.

● Install the clutch cover, tighten the clutch bolts to the

specified torque.
Clutch cover bolt: 10-15 N•m

● Re-adjust the clutch cable play. (Refer to page 2-8)

3-25
 ENGINE

OIL PUMP
REMOVAL AND INSPECTION
● Remove the clutch cover.
● Remove the oil pump driven gear circlip 10
1 .
● Remove the oil pump driven gear 2 .

● Remove the oil pump 3 .

● Check the O-ring for leakage or to see if missing. Replace it

with a new one if any defects are found.

● Rotate the play of oil pump by hand. Replace the oil pump if
there is something unusual.

REASSEMBLY
Reassemble the oil pump in the reverse order of
disassembly. Pay attention to the following points:
Lightly apply the engine oil inside the oil pump before
installing the oil pump.
Apply the Thread lock "1342" on the oil pump screws and
tighten.
99000- 32050 ：Thread lock“1342”

3-26
 ENGINE

GEAR SHIFTING MECHANISM

REMOVAL
● Remove the gear shifting lever 10
1 .
● Remove the clutch. (Refer to page 3-21)

Remove the gear shifting lever assembly 2 .

Remove the gear shifting fixing cam 3 and pin.

Remove the gear shifting fixing cam stopper 4 .

INSPECTION
Inspect the spring 5 for damage, gear shifting shaft 6 for
wear or bend.

REASSEMBLY
Reassemble the gear shifting mechanism in the reverse
order of disassembly. Pay attention to the following points:
● Install the gear shifting cam fixing cam and stopper.
Apply the Thread lock “1342" to the threaded part of the
mounting bolt.
99000-32050 ：Thread lock “1342”

3-27
 ENGINE

GENERATOR AND STARTER CLUTCH

REMOVAL
● Disconnect the generator coupler 10
1 and gear switch
coupler 2 .

● Remove the gear shifting lever bolt and take off the gear
shifting lever 3 .
● Remove the engine sprocket cover 4 .

Remove the reduction gear cover 5 .

Remove the reduction gear shaft 6 and starter reduction gear 7
.

Remove the generator wire pressure plate

Remove the generator cover 8 by removing the bolts.
Remove the gasket and dowel pins.

CAUTION
Loosen the generator cover bolts diagonally.
Be careful to the magneto force between the generator
(stator) and the rotor during the removing.

Remove the starter motor idle gear 9 and shaft.

3-28
 ENGINE

● Remove the generator rotor bolt with the special tool.

11F14-001 : Rotor holder

● Remove the generator rotor and key with the special tool.
● Remove the starter clutch gear and gasket.

11F14-002 : Generator rotor remover

CAUTION
Do not damage the key slot and crankshaft when
removing the key.

Remove the generator stator bolts , take off the generator stator 10.
Remove the trigger coil screws, take off the trigger coil 11 .

INSPECTION
● Install the starter driven gear onto the starter clutch and turn
the starter driven gear by hand to inspect the starter clutch for
a smooth movement. Te gear turns one direction only. If a
large resistance is felt to rotation, inspect the starter clutch for
damage or inspect the starter clutch contacting surface of the
starter driven gear for wear or damage. If they are found to be
damaged, replace them with new ones.

Inspect the starter driven gear spacer for damage. Replace

it with a new one if necessary.

3-29
 ENGINE

REASSEMBLY
Reassemble in the reverse order. Pay attention to the
following points:
● Apply the bond “1207b”to the generator stator grommet 10
11,
then install it to the generator cover.
99000-31140 : Bond " 1207B"
● Install the stator, apply the Thread lock to the bolt 2 then tighten it.
● Install the trigger coil, apply the Thread lock to the bolt 3 then tighten it.

99000-32050 : Thread lock " 1342"

Fit the key in the crankshaft slot.

Degrease the cone surface of rotor inner ring and
crankshaft, make sure the surface is dry and clean.

CAUTION

Take care not to damage the key slot and crankshaft

when installing the key.

● Align the rotor key slot with the key on the crankshaft,
install the rotor.
● Apply the Thread lock to the threaded part of bolt, tighten
the bolt to the specified torque.
99000-32050 : Thread lock " 1342"

Generator bolt : 40~50 N•m

11F14-001 : Rotor holder

● Install the gasket and dowel pins.

● Install the generator cover.

Replace the gasket with a new one to prevent

leakage.

3-30
 ENGINE

CRANKSHAFT, TRANSMISSION AND KICK STARTER

REMOVAL
● Remove the engine and drain the oil. (Refer to page 3-2)
● Remove the cylinder head and cylinder. (Refer to page 3-7)
● Remove the clutch and gear shifting mechanism. (Refer to
page 3-20)
● Remove the generator rotor and starter clutch. (Refer to page
3-26)

● Remove the cam chain 10

1.

● Remove the engine sprocket 2 .

● Remove the gear switch mounting screws, take off the gear
position switch 3 and pin, spring.
● Remove the crankshaft bearing pressure plate 4 , spring and
pin.

Remove the circlip and oil pump driven gear 5 .

Remove the washer, primary drive gear 6 , balancer drive gear 7 and
two keys.

Hold the balancer shaft with the special tool , remove the balancer
shaft nut .
Remove the adjust washer and flexous washer.

11F14-036 : Balancer shaft holder

3-31
 ENGINE

Remove the transmission assembly.

Remove the crankshaft with the special tool.

11F14-027 : Crankcase separating tool

Remove the balancer shaft.

Remove the kick starter assembly.

INSPECTION
Measure the conrod big end clearance with the thickness
gauge.

Conrod big end clearance:

Limit: 0.5 mm
09900-20803: Thickness gauge

Support the crankshaft with “V” blocks as shown, with the

two end journals resting on the blocks. Measure the
crankshaft runout with the dial gauge.

Crankshaft radial runout:

Limit: 0.05 mm
09900-20606:Dial gauge (1/100 mm)
09900-20701:Magnetic stand
09900-21304:V-block (100 mm)
3-32
 ENGINE

Remove the circlip, washer, balancer shaft driven ger

assembly 8 and spacer.
09900-06107 : Snap ring pliers (Open type)

● Remove the key and crankcase mounting bolts.

● Remove the right crankcase with the special tool.

● Fit the crankcase separating tool, so that the tool plate is
parallel with the end face of the crankcase.
11F14-027 : Crankcase separating tool

The crankshaft and transmission components must

remain in the left crankcase half. This is necessary
because the gear shifting cam stopper is mounted on
the left crankcase half and will damaged if the
gransmission components remain in the right half.

● Remove the gear shifting shaft, take off the gear shifting
forks.
● Remove the gear shifting cam

3-33
 ENGINE

Check if abnormal wear or poor lubrication exist on each

bush, inner race of gear and gear teeth surface.

● Inspect the kick starter shaft, kick starter, springs,spring

bush . Replace the part with new one if any defects are
found.

● Rotate the inner races of bearings with finger.

● Bearing rotation should be smooth and silent.
Simultaneously inspect if the bearing outer race rotates in
crankcase.
● In case of difficult rotation of the bearing inner race or
rotation of outer race, replace the bearing with a new one.

BEARING REMOVAL
● Remove the left and right half crankcases bearing fixing
plates.
● Remove the crankshaft bearings, counter shaft bearing
and drive shaft bearing from the left and right half
crankcases with the special tool,
09921-20240 : Bearing remover set

3-34
 ENGINE

● Wear on the big end of the conrod can be estimated by

checking the movement of the small end of the rod. This
method can also check the extent of wear on the parts of
the conrod’s big end.
Conrod deflection:
Limit: 3.0 mm
09900-20606 : Dial gauge (1/100 mm)
09900-20701 : Magnetic stand
09900-21304 : V-block
● Using a thickness gauge, check the shift fork clearance in
the groove of its gear. If the clearance limit is exceeded by
any of the three gears, determine whether the gear of the
gear shift fork should be replaced by measuring the
thickness and groove width.

Shifting fork to groove clearance: 0.45 mm

Checking clearance
09900-20803 : Thickness gauge

● Measure the thickness of gear shift fork.

Gear shift fork thickness: 4.93-5.0 mm

09900-20103: Vernier calipers

Measure thicknessChecking clearance

Measure the gear shift fork groove width.

The gear shift fork groove width: 5.1-5.18 mm

09900-20103: Vernier calipers

Checking groove width

Inspect the gear shifting guide slot for damage. Replace

the gear shifting guide slot if the damage is found.

3-35
 ENGINE

When mounting the crankshaft in the crankcase, it is

necessary to pull its left end into the crankcase.

09910-32812 : Crankcase installer

09910-20116 : Conrod holder
09910-32812-02: Crankshaft installer attachment.

CAUTION

Never fit the crankshaft into the crankcase by striking

it with a plastic hammer.
Always use the special tool, otherwise crankshaft
alignment accuracy will be affected.

TRANSMISSION

3-36
 ENGINE

REASSEMBLY
Reassemble in the reverse order of removal. Pay attention
to the follow points:

BEARING
Install the left and right crankcase bearing with the
special tool.

09913-70210 : Bearing installer set

Apply the Thread lock to the threaded part of bearing block

plate and tighten.
99000-32050 : Thread lock “1342”

CRANKSHAFT

Decide the width between the webs referring to the right

figure when rebuilding the crankshaft.

Width between webs:

Standard: 54.9-55.1 mm

55±0.1 mm

3-37
 ENGINE

Never reuse a circlip. After a circlip has been removed

from a shaft, it should be discarded and a new circlip
must be installed. When installing a new circlip, care
must be taken not to expand the end gap larger than
required to slip the circlip over the shaft. After
installing a circlip, always insure that it is completely
seated in its groove and securely fitted.

● Press-fit 2nd drive gear onto the counter shaft. Before

reassembling, coat the internal face of the 2nd drive gear
with THREAD LOCK “1303" and install it so that the length
A as shown in Fig.
Countershaft length A :
Standard:96.2-96.5 mm A

99000-32030: THREAD LOCK ”1303"

CAUTION
This procedure may be performed only twice before shaft
replacement is required.

GEAR SHIFTING CAM AND FORK

3-38
 ENGINE

● Fit the gear shifting cam to the crankcase, install the gear
shifting forks in order of “L, C, R”.

CAUTION
The gear shifting forks resemble each other very closely in
external appearance and configuration.Install them
according to mark “JBL, JBC, JBR”. Check to see if the
drive and driven shafts turn smoothly. Reassemble the gear
shifting mechanism if any defects are found.

Install the kick starer shaft assembly, tighten the stopper

bolt to the specified torque.

Stopper bolt : 25-30 N•m

Install the dowel pins and gasket.

CAUTION

Always use new gasket.

Fit the right half crankcase to the left half crankcase and
tighten crankcase mounting bolts.

CAUTION
Tighten the crankcase mounting bolts to specified
torque diagonally in 2-3 times.

3-39
 ENGINE

Install the dowel pin and gear shifting fixing cam,

Apply the Thread lock to threaded part of mounting bolts
before tightening.
Install the spring and gear shifting cam stopper.
Apply the Thread lock to threaded part of mounting bolts
before tightening.

99000-32050 : Thread lock “1342"

Install the balancer shaft driven gear assembly, hold the

balancer shaft with the special tool. Apply the Thread lock
to balancer nut and tighten it to the specified torque.

11F14-036: Balancer shaft fixing tool

99000-32050 : Thread lock “1342"

Stopper bolt: 25-35 N•m

Install the balancer shaft drive gear.

Align the mark A on the balance shaft drive gear with A B

the mark B on the balancer shaft driven gear.

Install the engine sprocket, apply the Thread Lock to the

sprocket bolt 10
1 and tighten.

99000-32050 : Thread lock "1342"

09930-40113 : Sprocket holder

3-40