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ENGWATER PUMP
Extent of removal Order Part name Q’ty Remarks
WATER PUMP DISASSEMBLY
Preparation for Crankcase cover (right)
Refer to “KICK AXLE, SHIFT SHAFT AND
removalPRIMARY DRIVE GEAR” section.
1 Water pump housing cover 1
2 Impeller shaft gear 1
3 Dowel pin 1Refer to “REMOVAL POINTS”.
4 Plain washer 1
5 Impeller shaft assembly 1
6 Bearing 1
Refer to “REMOVAL POINTS”.
7 Oil seal 2
EC4G0000
WATER PUMP
1
2
Extent of removal:1Impeller shaft removal2Oil seal removal
10 Nm (1.0 m•kg, 7.2 ft•lb)
10 Nm (1.0 m•kg, 7.2 ft•lb)
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4-49
ENGWATER PUMP
EC4G3000
REMOVAL POINTS
EC4G3210
Oil seal
NOTE:
9Replace the oil seal when transmission oil or
coolant leaks out from the water pump housing
hole at the bottom.
9Do not reuse the removed bearing and oil seal.
1. Remove:
9Bearing 1
2. Remove:
9Oil seal (outside) 1
9Oil seal (inside) 2
EC4G4000
INSPECTIONEC444200
Impeller shaft assembly
1. Inspect:
9Impeller shaft assembly1
Bend/Wear/Damage Replace.
Fur deposits Clean.
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4-50
ENGWATER PUMP
EC444300
Impeller shaft gear
1. Inspect:
9Gear teeth a
Wear/Damage Replace.
EC4H4600
Bearing
1. Inspect:
9Bearing 1
Rotate inner race with a finger.
Rough spot/Seizure Replace.
EC444400
Oil seal
1. Inspect:
9Oil seal 1
Wear/Damage Replace.
EC4G5000
ASSEMBLY AND INSTALLATION
EC4G5111
Oil seal
1. Install:
9Oil seal (inside) 1
9Oil seal (outside) 2
NOTE:
9Apply the lithium soap base grease on the oil
seal lip.
9Install the oil seal with its manufacture's marks or
numbers facing the crankcase cover (right) 3.
2. Install:
9Bearing 1
NOTE:
Install the bearing by pressing its outer race par-
allel.
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4-51
ENGWATER PUMP
EC4G5220
Impeller shaft assembly
1. Install:
9Impeller shaft assembly1
NOTE:
9Take care so that the oil seal lip is not dam-
aged or the spring does not slip off its position.
9When installing the impeller shaft assembly,
apply the lithium soap base grease on the oil
seal lip and impeller shaft assembly. And install
the shaft while turning it.
2. Install:
9Plain washer 1
9Dowel pin 2
9Impeller shaft gear 3
9Collar 4
9Plain washer 5
9Circlip 6
NOTE:
Install the Impeller shaft gear with the dowel pin
fitted in the groove ain the same gear.
3. Install:
9Dowel pin 1
9Gasket (water pump housing cover) 2
4. Install:
9Water pump housing cover 1
9Bolt (water pump housing cover) 2
9Copper washer (coolant drain bolt) 3
9Coolant drain bolt 4
10 Nm (1.0 m•kg, 7.2 ft•lb)
10 Nm (1.0 m•kg, 7.2 ft•lb)
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4-61
ENGCRANKCASE AND CRANKSHAFT
Extent of removal Order Part name Q’ty Remarks
CRANKCASE AND CRANKSHAFT
REMOVAL
Preparation for Engine Refer to “ENGINE REMOVAL”section.
removal Piston Refer to “
CYLINDER HEAD, CYLINDER
AND PISTON
” section.
Primary drive gear
Kick idle gearRefer to “
KICK AXLE, SHIFT SHAFT AND
Stopper leverPRIMARY DRIVE GEAR”section.
Rotor and stator Refer to “CDI MAGNETO” section.
1 Segment 1 Refer to “REMOVAL POINTS”.
2 Bolt [L=45 mm (1.77 in)] 6
3 Bolt [L=55 mm (2.17 in)] 4
4 Bolt [L=65 mm (2.56 in)] 1
5 Bolt [L=75 mm (2.95 in)] 1
6 Holder 1
7 Crankcase (right) 1 Use special tool.
8 Crankcase (left) 1 Refer to “REMOVAL POINTS”.
9 Crankshaft 1 Use special tool.
Refer to “REMOVAL POINTS”.
10 Oil seal 2
11 Bearing 2 Refer to “REMOVAL POINTS”.
EC4N0000
CRANKCASE AND CRANKSHAFT
12
3
Extent of removal:1Crankcase separation2Crankshaft removal
3Crankshaft bearing removal
30 Nm (3.0 m•kg, 22 ft•lb)10 Nm (1.0 m•kg, 7.2 ft•lb)
20 Nm (2.0 m•kg, 14 ft•lb)
14 Nm (1.4 m•kg, 10 ft•lb)
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4-64
ENGCRANKCASE AND CRANKSHAFT
Standard
Runout 0.03 mm 0.05 mm
limit: (0.0012 in) (0.0020 in)
Small end 0.8~1.0 mm 2.0 mm
free play: (0.031~0.039 in) (0.08 in)
Side 0.06~0.64 mm
—
clearance: (0.002~0.025 in)
Crank 55.90~55.95 mm
—
width: (2.201~2.203 in)
2. Inspect:
9Bearings 1
Rotate inner race with a finger.
Rough spot/Seizure Replace.
3. Inspect:
9Oil seal 1
Damage Replace.
EC4N4202
Crankshaft
1. Measure:
9Runout limit a
9Small end free play limit b
9Connecting rod big end side clearance c
9Crank width d
Out of specification Replace.
Use the dial gauge and a thickness gauge.
EC4N5000
ASSEMBLY AND INSTALLATION
EC4N5300
Crankshaft bearing
1. Install:
9Bearing 1
To crankcase (left and right).
NOTE:
Install the bearing by pressing its outer race
parallel.
Dial gauge:
YU-3097/90890-01252
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ENGCRANKCASE AND CRANKSHAFT
EC4N5102
Oil seal
1. Install:
9Oil seal (left) 1
9Oil seal (right) 2
NOTE:
9Apply the lithium soap base grease on the oil
seal lip.
9Install the oil seal with its manufacture’s marks
or numbers facing outward.
EC4N5272
Crankshaft
1. Install:
9Crankshaft 1
Use the crankshaft installing tool 2, 3, 4
åFor USA and CDN
∫Except for USA and CDN
NOTE:
9Hold the connecting rod at top dead center with
one hand while turning the nut of the installing
tool with the other. Operate the installing tool
until the crankshaft bottoms against the bear-
ing.
9Before installing the crankshaft, clean the con-
tacting surface of crankcase.
9Apply the lithium soap base grease on the oil
seal lip.
cC
Do not use a hammer to drive in the crank-
shaft.
Crankshaft installing tool:
Pot 2 2
:
YU-90050/90890-01274
Bolt 3 3
:YU-90050/90890-01275
Adapter 4 4
:YU-90063/90890-01278
å∫
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8. Install:
9Segment 1
9Bolt (segment) 2
NOTE:
9When installing the segment onto the shift cam
3, align the punch mark awith the dowel pin
b.
9Turn the segment clockwise until it stops and
tighten the bolt.
9. Remove:
9Sealant
Forced out on the cylinder mating surface.
10. Apply:
9Engine oil
To the crank pin, bearing, oil delivery hole
and connecting rod big end washer.
11. Check:
9Crankshaft and transmission operation
Unsmooth operation Repair.
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ENGCRANKCASE AND CRANKSHAFT
30 Nm (3.0 m•kg, 22 ft•lb)
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