Fit the steel balls into the 5th gear holes in the output shaft.
5th Gear [A] Output Shaft [B] Steel Balls [C]
NOTICE
Do not apply grease to the balls to hold them in place. This will cause the positive neutral finder mechanism to malfunction.
After assembling the 5th gear with steel balls in place on the output shaft, check the ball-locking effect that the 5th gear does not come out of the output shaft when moving it up and down by hand.
1. 1st Gear
2. 2nd Gear
3. 3rd Gear
4. 4th Gear
5. 5th Gear
6. 6th (Top) Gear
7. Drive Shaft
8. Output Shaft
9. Circlip (Turn the punch mark to the gear.)
10. Toothed Washer
11. Toothed Washer
12. Toothed Bushing, L = 15 mm (0.60 in.)
13. Toothed Washer
14. Circlip (Turn the punch mark to the washer.)
15. Bushing, 31 mm (1.2 in.)
16. Toothed Bushing, L = 9.4 mm (0.37 in.)
17. Washer
18. Bushing, 25 mm (1.0 in.)
Shift Drum and Fork Removal
Refer to the Transmission Assy Disassembly.
Shift Drum and Fork Installation
Refer to the Transmission Assy Assembly.
Piston Installation
Apply molybdenum disulfide oil solution to the oil ring expander,
and install the oil ring expander [A] in the bottom
piston ring groove so the ends [B] not butt together
Applymolybdenum disulfide oil solution to the oil ring steel
rails, and install the oil ring steel rails, one above th ...
Rebound Damping Force Adjustment
To adjust the rebound damping force, turn the rebound
damping adjuster [A] to the desired position.
The standard adjuster setting is the 1 3/4 turns out from
the fully clockwise position.
Rebound Damping Force Adjustment
...
Intake Air Pressure Sensor #1 Removal
NOTICE
Never drop the intake air pressure sensor #1 especially
on a hard surface. Such a shock to the sensor
can damage it.
Remove:
Air Cleaner Housing (see Air Cleaner Housing Removal
in the Fuel System (DFI) chapter)
Intake Air Pressure Sensor #1 Connector [A]
Remove the intake air ...