Piston ring to cylinder clearance Insert the piston ring at the bottom of the bore where minimum wear occurs taking care to position it squarely and measure end gap. Use the suitable tool 5 to prevent rotation and tighten to 60 Nm, 6 Kgm, 43. Piston diameter Measure piston diameter Dp 7 mm 0. Clutch plates should show no signs of bluing, scoring or distortion. Be careful that no brake fluid or any oil gets on brake pads or discs.
Plate thickness when new: 3. Do not compress the springs too much or they will weaken. If the chain becomes badly worn or is poorly adjusted i. Side panel removal Remove the saddle as described in the relevant paragraph. Clean lock ring nut 4 and adjuster ring nut 5 of the spring 6. Install the fork shafts 7 and 8 and make sure the forks move freely. .
Place the shaft on two identical reference blocks. Remove reservoir cap 2 and gasket 3 and operate the control lever 4 until draining all fluid. The ignition is an integrated digital electronic ignition system with static timing and advance using intermittent sequential phased electronic injection feed. Dis- engage the return spring 4 of the rear brake pedal from the chassis. Note: to facilitate removal, quickly but carefully pump the tubes back and forth until separating them. Use an Allen wrench to loosen the 6 screws 1 and remove the pump 2.
Install the head 1 while supporting the timing chain 2 with a screwdriver. Hold the sprocket 4 with the suitable tool 7 to prevent rotation and tighten the nut 6 use a 22 mm wrench, 100 Nm, 10 Kgm, 72. If they need adjusting, loosen the check nuts 2 and turn the adjuster screws 3. Connecting rod small or big end seized Replace 3. Threads, keyways and splines must be in good condition. If measured clearance exceeds the service limit, replace clutch plates or housing and repeat measurement. Spark plug electrode gap too close Adjust overheat 2.
Servicing the rear suspension drop and drag link With drop link 1 and drag link 2 still in place connected to swinging arm and chassis, respectively , rock them both back and forth in all directions to check for. Refit the ratchet assembly 10 together with the plate, making sure ratchets and springs are in the correct positions. Replacement pistons come with piston rings and piston pin. Check the O-rings of the oil suction stub 3 and replace them if needed. Be careful not too damage the mating surfaces that contact the gasket or those of the combustion chamber. Grease helps to accumulate dust and mud, which act as abrasive and help to rapidly wear out the chain, the front and rear sprockets. H02350 Remove the rotor 2 using the puller 3A part no.
Spring removal: clamp the shock absorber in a vice taking care to avoid distorting it. Remove the input shaft 8 and output shaft 9 being careful not to lose any shims if fitted. Free play a must be at least 3 mm. Route the rear end of the wiring 28 as shown in the figure. Measure current across the negative terminal of the battery and the negative cable using a meter.
Remove the cover 3 together with its filter 5 and Belleville washer 6. Fit 2nd gear 2 , washer 3 and retaining ring 4. It should be about 145 mm 5. Replace any part found to be faulty. If not tightened securely, a nut or a screw might become damaged or work itself loose, causing damage to motorcycle and injury to rider. Tank removal Remove the screws 1 and the side panels. Fit roller cage 8 and 3rd gear 9.
Remove springs, pressure plate 5 with bearing 6 and clutch actuator plate 7. Tap the output shaft 5 with a rubber hammer at intervals during removal to keep the crankcase half from getting stuck. Bent clutch plates Replace Gears do not engage 1. Straighten the tab of the lock washer 10. Disassemble the starter motor as outlined in the relevant paragraph. Clamp the camshaft between centres and check deviation using two dial gauges. H02184 Disconnect the supply hose 8 from the outlet fitting 9 on the fuel pump, located in the rear bottom section of the tank.
Disconnect the positive power supply cable 1 loosening the hexagonal-head screw 8 mm wrench. Apply Prussian Blue to the valve and rotate it in its seat using a rubber hose or other similar tool. Remove the retaining screw 2 of the gear shift pedal 1 8 mm wrench and slide the pedal from the selector shaft. Remove the retaining screws 2 and then the coil 3. Note 2: Before sliding the sealing ring over the inner tube, cover tube edge with plastic as shown in the figure.