If the guide pin on any shift fork is less than the service limit, the fork must be replaced.
Shift Fork Guide Pin Diameter
Standard: 6.9 
7.0 mm (0.272
0.276 in.)
Service Limit: 6.8 mm (0.268 in.)
If any shift drum groove is worn over the service limit, the drum must be replaced.
Shift Drum Groove Width
Standard: 7.05 
7.20 mm (0.278
0.283 in.)
Service Limit: 7.3 mm (0.287 in.)
Shift Fork/Gear Groove Wear Inspection
Gear Dog and Gear Dog Hole
Damage InspectionCaliper Installation
Install the caliper and brake hose lower end.
For the front caliper, be sure to install the collars [A].
Replace the washers on each side of hose fitting with new
ones.
Touch the brake hoses [A] to the stopper [B] of the caliper.
Front Calipers [C]
Rear Caliper [D]
Tighten:
To ...
Fuel Injector Fuel Line Inspection
Remove:
Fuel Tank (see Fuel Tank Removal)
Air Cleaner Housing (see Air Cleaner Housing Removal)
Disconnect:
Primary and Secondary Fuel Hoses (see Fuel Hose Replacement
in the Periodic Maintenance chapter)
Do not remove the nozzle assy from the air cleaner housing.
Be sure to pla ...
Gear Position Switch Installation
Securely place the springs [A] and pins [B] into the holes
[C] of the shift drum.
Apply grease to the new O-ring [D].
Install the gear position switch [E].
Apply a non-permanent locking agent to the threads of
the gear position switch screws [F].
Tighten:
Torque - Gear Position Swit ...