Engine Installation
Exploded ViewCylinder (Upper Crankcase) Wear Inspection
Split the crankcase (see Crankcase Splitting).
Remove the pistons (see Piston Removal).
Assemble the cylinder (upper crankcase) [A], the cylinder
head [B] and the cylinder head gasket [C].
Tighten the cylinder head bolts (see Cylinder Head Installation
in the Engine Top End chapter).
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Fuel Level Warning Indicator Light
: The fuel level warning
indicators
are activated when approximately 3.8 L
(1.0 US gal) of fuel remains as follows:
For models without KIBS:
A. Fuel Level Warning Indicator Light
B. “FUEL” Indication
The fuel level warning indicator light
( ) goes
on and “FUEL” blinks in the
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Shift Fork/Gear Groove Wear Inspection
Measure the thickness of the shift fork ears [A], and measure
the width [B] of the gear grooves.
If the thickness of a shift fork ear is less than the service
limit, the shift fork must be replaced.
Shift Fork Ear Thickness
Standard: 5.7 6.0 mm (0.224
0.236 in.)
Service Limit: 5.6 mm ...