5-37
OIL FILTER ELEMENT AND WATER PUMP
2. Install:
• Right crankcase cover "1"
•Bolt "2"
•Bolt
• Apply the engine oil on the impeller
shaft end.
• When installing the crankcase cov-
er onto the crankcase, be sure that
the impeller shaft end "2" aligns
with the balancer end slot "3".
• Tighten the bolts in stage, using a
crisscross pattern.
INSTALLING THE KICKSTARTER
CRANK
1. Install:
• Kickstarter crank "1"
• Washer
• Bolt (kickstarter crank)
Install so that there is a clearance "a"
of 8 mm (0.31 in) or more between
the kickstarter and frame and that the
kickstarter does not contact the
crankcase cover when it is pulled.
2. Install:
• Oil tank breather hose "1"
•Clamp "2"
INSTALLING THE WATER PUMP
HOUSING
1. Install:
• Dowel pin "1"
• O-ring "2"
Apply the lithium soap base grease
on the O-ring.
2. Install:
• Water pump housing "1"
• Bolt (water pump housing) "2"
• Washer "3"
• Coolant drain bolt "4"3. Install:
• O-ring
• Coolant pipe "1"
• Bolt (coolant pipe) "2"
Apply the lithium soap base grease
on the O-ring.
INSTALLING THE OIL FILTER
ELEMENT
1. Install:
• Oil filter element "1"
• O-ring "2"
• Oil filter element cover "3"
• Bolt (oil filter element cover)
Apply the lithium soap base grease
on the O-ring.
Bolt:
12 Nm (1.2 m•kg, 8.7
ft•lb)
Bolt:
10 Nm (1.0 m•kg, 7.2
ft•lb)
Bolt (kickstarter crank):
33 Nm (3.3 m•kg, 24
ft•lb)Clamp:
2 Nm (0.2 m•kg, 1.4
ft•lb)
Bolt (water pump hous-
ing):
10 Nm (1.0 m•kg, 7.2
ft•lb)
Coolant drain bolt:
10 Nm (1.0 m•kg, 7.2
ft•lb)
Bolt (coolant pipe):
10 Nm (1.0 m•kg, 7.2
ft•lb)
Bolt (oil filter element
cover):
10 Nm (1.0 m•kg, 7.2
ft•lb)
6-6
FRONT BRAKE AND REAR BRAKE
FRONT BRAKE AND REAR BRAKE
REMOVING THE FRONT BRAKE
Order Part name Q'ty Remarks
Hold the machine by placing the suitable stand
under the engine.Refer to "HANDLING NOTE".
Drain the brake fluid. Refer to removal section.
1 Brake hose holder (protector) 2
2 Brake hose holder (brake caliper) 1
3 Union bolt 2
4 Brake hose 1
5 Pad pin plug 1 Remove when loosening the pad pin.
6Pad pin 1Loosen when disassembling the brake cali-
per.
7 Brake caliper 1
8Brake lever 1
9 Brake master cylinder bracket 1
10 Brake master cylinder 1
6-7
FRONT BRAKE AND REAR BRAKE
REMOVING THE REAR BRAKE
Order Part name Q'ty Remarks
Hold the machine by placing the suitable stand
under the engine.Refer to "HANDLING NOTE".
Rear wheel Refer to "FRONT WHEEL AND REAR
WHEEL" section.
Drain the brake fluid. Refer to removal section.
1 Brake pedal 1
2 Brake master cylinder 1
3 Brake hose holder 2
4 Union bolt 2
5 Brake hose 1
6 Pad pin plug 1 Remove when loosening the pad pin.
7Pad pin 1Loosen when disassembling the brake cali-
per.
8 Brake caliper 1
6-17
FRONT FORK
DISASSEMBLING THE FRONT FORK
Order Part name Q'ty Remarks
1 Front fork cap bolt 1 Refer to removal section.
2 Fork spring 1 Drain the fork oil.
3 Dust seal 1 Refer to removal section.
4 Stopper ring 1 Refer to removal section.
5 Inner tube 1 Refer to removal section.
6 Outer tube 1
7 Piston metal 1
8 Slide metal 1
9 Oil seal washer 1
10 Oil seal 1
11 Spring guide 1
12 Base valve 1 Refer to removal section.
13 Damper rod 1 Refer to removal section.
