ENGINE ASSEMBLY AND SETTING
5-52
ENG
4. Tighten:
•Screws (crankcase) (1) ~ (14)
NOTE:
Tighten the screws beginning with the one with
the lowest number.
Screw (crankcase): 10 Nm (1.0 mkg)
Stopper lever screw (4):
10 Nm (1.0 mkg)
5. Apply:
•4-stroke engine oil
(to the connecting rod pin, the bearing and
the oil passage).
6. Check:
•Gearbox and transmission functioning
Jerky functioning ➔Replace.
SHIFT SHAFT AND OIL PUMP
1. Install
•Spring (1)
•Collar (2)
•Stopper lever (3)
NOTE:
Place the stopper lever and the spring in the cor-
rect position.
2. Install:
•Plate washer (1)
•Spring (2)
•Shift lever (3)
•Circlip (4)
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DIFFICULTIES IN SHIFTING
8-4
TRBL
SHTG
?
Clutch
Engine oil PROBABLE CAUSES•Clutch cable wrongly set
•Wrong position of push lever
•Irregular engagement of push lever and push
rod
•Pressure plate deformed
•Clutch springs not preloaded uniformly
•Reference marks not aligned
•Push rod broken
•Clutch gear assy nut loose or push rod deformed
•Primary driven gear bearing defective
•Driven plates deformed
•Driving plates deformed
•Clutch cable damaged
•Oil level over maximum
•Incorrect gradation (high viscosity)
•Degradation
SHIFTING IMPOSSIBLE
DIFFICULTIES IN SHIFTING
Shift shaft
Shift cam, shift fork PROBABLE CAUSES•Shift shaft deformed
•Groove with impurities or foreign bodies
•Shift fork stuck
•Shift fork guide bar deformed
THE SHIFT PEDAL FAILS TO MOVE
Transmission•Transmission gears struck
•Gears stuck by impurities or foreign bodies
•Wrong transmission assembly
Shift shaft
Shift fork PROBABLE CAUSES•Shift lever set wrongly
•Shift cam
stop lever fails to return freely
•Shift forks worn
Transmission
•Gear clutches worn
DISENGAGING GEARS
Shift cam
•Shaft cam with thrust free play
•Shift cam groove worn
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