Page 249 of 362
SHIFT SHAFT
5-54
4. Tighten:
• Shift guide bolt “1”
EASB111262INSTALLING THE SHIFT SHAFT
1. Install:
• Roller “1”
• Stopper lever “2” (to shift shaft)
• Collar “3” (to shift shaft)
• Shift shaft “4”
TIP
Apply the engine oil on the roller and shift shaft.
2. Install:
• Oil seal
EASB111263INSTALLING THE SHIFT PEDAL
1. Install:
• Shift pedal
• Shift pedal
TIP
Align the punch mark “a” on the shift shaft with
the punch mark “b” in the shift pedal.Shift guide bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
LOCTITE®
Shift pedal bolt
12 Nm (1.2 m·kgf, 8.7 ft·lbf)
T R..
1 1
LT
E
E
1
23
4
New
T R..
a
12b
Page 253 of 362
OIL PUMP AND BALANCER GEAR
5-58
3. Check:
• Oil pump operation
Rough movement Repeat steps (1) and
(2) or replace the defective part(s).
EASB111269
ASSEMBLING THE OIL PUMP
1. Install:
• Oil pump drive shaft “1”
• Inner rotor “2”
• Dowel pin “3”
TIP
• Apply the engine oil on the oil pump drive
shaft and inner rotor.
• Fit the dowel pin into the groove in the inner
rotor.
2. Install:
• Outer rotor “1”
TIP
Apply the engine oil on the outer rotor.
3. Install:
• Oil pump cover “1”
• Oil pump cover screw “2” Inner-rotor-to-outer-rotor-tip
clearance
Less than 0.150 mm (0.0059 in)
Limit
0.20 mm (0.0079 in)
Outer-rotor-to-oil-pump-housing
clearance
0.13–0.18 mm (0.0051–0.0071 in)
Limit
0.24 mm (0.0094 in)
Oil-pump-housing-to-inner-and-
outer-rotor
clearance
0.06–0.11 mm (0.0024–0.0043 in)
Limit
0.17 mm (0.0067 in)
1. Inner rotor
2. Outer rotor
3. Oil pump housing
b
a 1
2
3
c
Oil pump cover screw
2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
21
3
1
E
T R..
2
1
Page 254 of 362
OIL PUMP AND BALANCER GEAR
5-59
EASB111270INSTALLING THE OIL PUMP AND BALANC-
ER GEAR
1. Install:
• Oil pump assembly “1”
• Oil pump assembly bolt “2”
ECA1DX1023
NOTICE
After tightening the bolts, make sure that
the oil pump turns smoothly.
2. Install:
• Balancer weight gear “1”
TIP
Install the balancer weight gear and balancer
shaft with their lower splines “a” aligning with
each other.
3. Install:
• Balancer drive gear “1”
TIP
• Align the punched mark “a” on the balancer
drive gear with the punched mark “b” on the
balancer weight gear.
• Install the balancer drive gear and crankshaft
with the lower splines “c” aligning with each
other.4. Install:
• Lock washer “1”
• Balancer weight gear nut “2”
• Primary drive gear “3”
• Conical washer “4”
• Primary drive gear nut “5”
• Straight key “6”
•Balancer “7”
• Lock washer “8”
• Balancer nut “9”
TIP
• Apply engine oil to the contact surface and
threaded portion of the primary drive gear nut.
• Apply engine oil to the contact surfaces of the
conical washer.
• Place an aluminum plate “a” between the
teeth of the balancer drive gear “10” and bal-
ancer weight gear “11”.
• Install the conical washer with its convex sur-
face “b” outward. Oil pump assembly bolt
5 Nm (0.5 m·kgf, 3.6 ft·lbf)
LOCTITE®
T R..
1
2
LT
Balancer weight gear nut
50 Nm (5.0 m·kgf, 36 ft·lbf)
Primary drive gear nut
100 Nm (10 m·kgf, 72 ft·lbf)
Balancer nut
45 Nm (4.5 m·kgf, 33 ft·lbf)
New
T R..
New
T R..
New
T R..
1
2 11
10
a
Page 256 of 362
AC MAGNETO
5-61
EASB111271
AC MAGNETO
Removing the AC magneto
Order Part name Q’ty Remarks
Engine oilDrain.
Refer to “CHANGING THE ENGINE OIL” on
page 3-15.
Seat Refer to “GENERAL CHASSIS” on page 4-1.
Air scoop (left) Refer to “GENERAL CHASSIS” on page 4-1.
1 AC magneto coupler 1 Disconnect.
2 Crankshaft position sensor coupler 1 Disconnect.
3 Shift pedal 1
4 Left crankcase cover 1
5 Gaskets 1
6 Dowel pin 2
7Holder 1
8 Stator assembly 1
9 Rotor 1
10 Woodruff key 1
For installation, reverse the removal proce-
dure.
110
2
4 7 5 8 3
96
12 Nm (1.2 m kgf, 8.7 ft Ibf)T.R.
8 Nm (0.8 m kgf, 5.8 ft Ibf)T.R.
8 Nm (0.8 m kgf, 5.8 ft Ibf)T.R.
65 Nm (6.5 m kgf, 47 ft Ibf)T.R.
New
LT
6
LT
LT
10 Nm (1.0 m kgf, 7.2 ft Ibf)T.R.
10 Nm (1.0 m kgf, 7.2 ft Ibf)T.R.
Page 259 of 362
CRANKCASE
5-64
EASB111276
CRANKCASE
Separating the crankcase
Order Part name Q’ty Remarks
Engine Refer to “ENGINE REMOVAL” on page 5-1.
PistonRefer to “CYLINDER AND PISTON” on page
5-33.
BalancerRefer to “OIL PUMP AND BALANCER
GEAR” on page 5-55.
Kick shaft assembly Refer to “KICKSTATER” on page 5-47.
Segment Refer to “SHIFT SHAFT” on page 5-50.
Stator Refer to “AC MAGNETO” on page 5-61.
1 Timing chain guide (exhaust side) 1
2 Timing chain guide stopper plate 1
3 Timing chain 1
4 Bolt [L = 45 mm (1.77 in)] 6
5 Bolt [L = 65 mm (2.56 in)] 4
6 Bolt [L = 75 mm (2.95 in)] 2
7 Right crankcase 1
8 Left crankcase 1
9 Dowel pin 2
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)T.R.
12 Nm (1.2 m•kgf, 8.7 ft•Ibf)T.R.
12 Nm (1.2 m•kgf, 8.7 ft•Ibf)T.R.
12 Nm (1.2 m•kgf, 8.7 ft•Ibf)T.R.
3
1 5
2
6410 55
4
4
446
97
8
9
LT
Page 262 of 362
CRANKCASE
5-67
EASB111277DISASSEMBLING THE CRANKCASE
1. Separate:
• Right crankcase
• Left crankcase
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the crankcase bolts.
TIP
Loosen each bolt 1/4 of a turn at a time and af-
ter all the bolts are loosened, remove them.
b. Remove the right crankcase “1”.
TIP
• Place the crankcase with its left side down-
ward and split it by inserting a screwdriver tip
into the splitting slit “a” in the crankcase.
• Lift the right crankcase horizontally while light-
ly patting the crankcase splitting slit and the
engine mounting boss using a soft hammer,
and leave the crankshaft and the transmission
with the left crankcase.
ECA33DD041
NOTICE
Use soft hammer to tap on the case half.
Tap only on reinforced portions of case. Do
not tap on gasket mating surface. Work
slowly and carefully. Make sure the case
halves separate evenly. If the cases do not
separate, check for a remaining case bolt or
fitting. Do not force.c. Remove the dowel pins and O-ring.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EASB111278REMOVING THE CRANKCASE BEARING
1. Remove:
• Bearing “1”
TIP
• Remove the bearing from the crankcase by
pressing its inner race.
• Do not use the removed bearing.
EASB111279CHECKING THE TIMING CHAIN, TIMING
CHAIN GUIDE, OIL STRAINER
1. Check:
• Timing chain
Stiffness Replace the camshaft sprocket,
timing chain and crankshaft sprocket as a
set.
2. Check:
• Timing chain guide
Damage/wear Replace
1
a
Page 267 of 362
TRANSMISSION
5-72
EASB111287
TRANSMISSION
Removing the transmission, shift drum assembly, and shift forks
Order Part name Q’ty Remarks
Engine Refer to “ENGINE REMOVAL” on page 5-1.
CrankcaseSeparate.
Refer to “CRANKCASE” on page 5-64.
1 Main axle 1
2 Drive axle 1
3 Long shift fork guide bar 1
4 Short shift fork guide bar 1
5Spring 4
6 Shift cam 1
7 Shift fork 3 (R) 1
8 Shift fork 2 (C) 1
9 Shift fork 1 (L) 1
10 Collars 1
For installation, reverse the removal proce-
dure.
2
10
1
53
4 578
69
M
M
M
M
M
EE
E
E
LS
New
Page 270 of 362
TRANSMISSION
5-75
2. Install:
• Collar “1”
• 2nd wheel gear (23T) “2”
• 4th wheel gear (24T) “3”
• 3rd wheel gear (26T) “4”
• 5th wheel gear (20T) “5”
• Collar “6”
• 1st wheel gear (27T) “7”
• O-rings “8”
(to the drive axle “9”)
TIP
• Before installation, apply molybdenum disul-
fide oil to the inner and end surface of the idler
gear and to the inner surface of the sliding
gear, then install.
• Apply the lithium-soap-based grease on the
O-ring.
3. Install:
• Washer “1”
• Circlip “2”
TIP
• Be sure the circlip sharp-edged corner “a” is
positioned opposite side to the washer and
gear “b”.
• Install the circlip with its ends “c” settled even-
ly on the spline crests.4. Install:
• Collar “1”
TIP
• Apply the lithium-soap-based grease on the
oil seal lip.
• When installing the collar into the crankcase,
pay careful attention to the crankcase oil seal
lip.
5. Install:
• Main axle “1”
• Drive axle “2”
TIP
• Install to the left crankcase simultaneously.
• Apply engine oil to the main axle and the drive
axle bearing.
New
298
3
4
5
6
7
New
M
LS
1
New
21
2
ab
cc
1
2
EE
