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Maximum secondary shaft runout 0.08 mm (0.0031 in)
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5 - 85
TRANSMISSION ENG
8. Check:
• transmission gears
Blue discoloration/pitting/wear → Replace the defective gear(s).
9. Check:
• transmission gear movement
Rough movement → Replace the defective part(s).
10. Check:
• circlips
Damage/bends/looseness → Replace.
EAS00418
ASSEMBLING THE CRANKCASE
Refer to “CRANKCASE AND CRANKSHAFT”.
5 - 86
CHAIN DRIVE ENG
CHAIN DRIVE
| Order | Job/Part | Q’ty | Remarks | ||
| Removing the chain drive assembly | Remove the parts in the order listed. | ||||
| Chain drive oil | Drain. | ||||
| Refer to “CHANGING THE CHAIN | |||||
| DRIVE OIL” in chapter 3. | |||||
| Rear shock absorber | Refer to “REAR SHOCK ABSORBER” in | ||||
| chapter 4. | |||||
| Rear brake caliper/rear wheel | Refer to “REAR WHEEL AND BRAKE | ||||
| DISC” in chapter 4. | |||||
| Rear brake hose/rear brake lock lever | |||||
| cable holder | |||||
| Cover | |||||
| Nut | |||||
| Washer | Refer to “INSTALLING THE CHAIN | ||||
| Swingarm | |||||
| DRIVE”. | |||||
| Dowel pin | |||||
| Pivot shaft | |||||
5 - 87
CHAIN DRIVE ENG
| Order | Job/Part | Q’ty | Remarks |
| Collar | |||
| Oil seal | |||
| Bearing | |||
| Left rear footrest | |||
| Chain drive assembly | |||
| Chain drive holder assembly | |||
| O-ring | |||
| For installation, reverse the removal pro- | |||
| cedure. | |||
5 - 88
CHAIN DRIVE ENG
| Order | Job/Part | Q’ty | Remarks |
| Disassembling the chain drive | Remove the parts in the order listed. | ||
| assembly | |||
| Chain drive case (outer) | |||
| Secondary drive chain | |||
| Secondary drive gear | |||
| Secondary driven gear | |||
| Middle shaft | |||
| Primary drive chain | |||
| Primary drive gear | |||
| Primary driven gear | |||
| Bearing | |||
| Oil seal | |||
| A | Collar | ||
| B | Chain drive case (inner) | ||
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5 - 89
CHAIN DRIVE ENG
| Order | Job/Part | Q’ty | Remarks |
| C | Retainer | ||
| For assembly, reverse the disassembly | |||
| procedure. | |||
5 - 90
CHAIN DRIVE ENG
4 2
CHECKING THE SWINGARM
20 Check:
swingarm 1 Damage/wear → Replace.
27 Check:
pivot shaft 1
collar
bearing
oil seal
Damage/wear → Replace.
CHECKING THE CHAIN DRIVE ASSEMBLY
S Check:
primary drive chain 1
secondary drive chain 2
Damage/stiffness → Replace the drive chain and its respective gears as a set.
T Check:
primary drive gear 3
primary driven gear 4
secondary drive gear 5
secondary driven gear 6
Damage/wear → Replace the respective drive gears and respective drive chains as a set.
ASSEMBLING THE CHAIN DRIVE
ASSEMBLY
EE Install:
chain drive case (outer)
| T.R. | 10 Nm (1.0 m · kg, 7.2 ft · lb) |
NOTE:
First, tighten the chain drive case bolts that are numbered in the illustration in the order shown, and then tighten the unnumbered bolts in a crisscross pattern.
5 - 91
CHAIN DRIVE ENG
INSTALLING THE CHAIN DRIVE
15. Install:
chain drive assembly
swingarm
pivot shaft
washer
nut
16. Tighten:
swingarm bolt
T.
R.
40 Nm (4.0 m · kg, 29 ft · lb)
• Tighten:
pivot shaft
nut
NOTE:
T.
R.
T.
R.
7 Nm (0.7 m · kg, 5.1 ft · lb)
100 Nm (10.0 m · kg, 72 ft · lb)
1 With your fingers, screw in the pivot shaft until it touches the collar and then tighten the pivot shaft to the tightening torque.
1 Tighten the nut to the tightening torque.
1 Install the shock absorber and rear wheel after the swingarm is installed.
• Fill:
chain drive oil
Refer to “CHANGING THE CHAIN DRIVE OIL” in chapter 3.
• Check:
chain drive oil level
Refer to “CHECKING THE CHAIN DRIVE OIL LEVEL” in chapter 3.
5 - 92
COOL 6
| COOL | ||||
| CHAPTER 6 | ||||
| COOLING SYSTEM | ||||
| RADIATOR AND OIL COOLER...................................................................... | 6-1 | |||
| CHECKING THE RADIATOR.................................................................... | 6-3 | |||
| CHECKING THE OIL COOLER................................................................ | 6-4 | |||
| INSTALLING THE OIL COOLER AND RADIATOR.................................. | 6-4 | |||
| THERMOSTAT................................................................................................ | 6-6 | |||
| CHECKING THE THERMOSTAT.............................................................. | 6-7 | |||
| INSTALLING THE THERMOSTAT............................................................ | 6-7 | |||
| WATER PUMP................................................................................................. | 6-9 | |||
| DISASSEMBLING THE WATER PUMP.................................................. | 6-12 | |||
| CHECKING THE WATER PUMP............................................................ | 6-13 | |||
| ASSEMBLING THE WATER PUMP........................................................ | 6-13 | |||
| INSTALLING THE WATER PUMP.......................................................... | 6-15 |
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COOL 
RADIATOR AND OIL COOLER COOL
COOLING SYSTEM
RADIATOR AND OIL COOLER
| Order | Job/Part | Q’ty | Remarks |
| Removing the radiator and oil cooler | Remove the parts in the order listed. | ||
| Footrest board/leg shield/inner fender | Refer to “COVER AND PANEL” in chap- | ||
| ter 3. | |||
| Engine oil | Drain. | ||
| Refer to “CHANGING THE ENGINE OIL” | |||
| in chapter 3. | |||
| Coolant | Drain. | ||
| Refer to “CHANGING THE COOLANT” in | |||
| chapter 3. | |||
| Coolant reservoir hose | |||
| Coolant reservoir | |||
| Cooling system air bleed hose | |||
| Oil cooler outlet hose | |||
| Radiator inlet hose | |||
| Thermostat outlet hose | Disconnect. | ||
6 - 1
RADIATOR AND OIL COOLER COOL
| Order | Job/Part | Q’ty | Remarks |
| Coolant pipe | |||
| Fast idle outlet hose | Disconnect. | ||
| Radiator outlet hose | Disconnect. | ||
| Radiator fan motor coupler | Disconnect. | ||
| Radiator filler neck | |||
| Radiator filler hose | |||
| Stay | |||
| Radiator | |||
| Radiator fan | |||
| Oil filter cartridge | |||
| Oil cooler inlet hose | Disconnect. | ||
| Oil cooler | Refer to “INSTALLING THE OIL | ||
| COOLER AND RADIATOR”. | |||
| For installation, reverse the removal pro- | |||
| cedure. | |||
6 - 2
RADIATOR AND OIL COOLER COOL
EAS00455
CHECKING THE RADIATOR
21 Check:
radiator fins Obstruction → Clean.
Apply compressed air to the rear of the radi-
ator.
Damage → Repair or replace.
NOTE:
Straighten any flattened fins with a thin, flat-head screwdriver.
11) Check:
radiator hoses Cracks/damage → Replace.
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10) Measure:
radiator cap opening pressure
Below the specified pressure → Replace the radiator cap.
Radiator cap opening pressure 107.9 ~ 137.3 kPa
(1.08 ~ 1.37 kg/cm2,
15.6 ~ 19.9 psi)
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• Install the radiator cap tester 1 and radiator cap tester adapter 2 onto the radiator cap
3.
Radiator cap tester 90890-01325, YU-24460-01
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