Before completing any service on the motorcycle, disconnect the battery cables from the battery to prevent the engine from accidentally turning over. Disconnect the ground cable (–) first and then the positive (+). When completed with the service, first connect the positive (+) cable to the positive (+) terminal of the battery then the negative (–) cable to the negative terminal.
Edges of Parts
Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts.
Solvent
Use a high flash-point solvent when cleaning parts. High flash-point solvent should be used according to directions of the solvent manufacturer.
Before Servicing
Cleaning Vehicle before DisassemblyPiston Wear Inspection
Measure the outside diameter [A] of each piston 5 mm
(0.20 in.) [B] up from the bottom of the piston at a right
angle to the direction of the piston pin.
If the measurement is under service limit, replace the piston.
Piston Diameter
Standard: 75.959 75.974 mm
(2.9905 2.9911 in.)
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Check 3-6: Neutral Indicator Light (LED) Inspection
Connect the leads in the same circuit as Check 3-2.
Connect the terminal [8] to the battery (–) terminal.
Check that the neutral indicator light (LED) [A] goes on.
If the indicator light does not go on, replace the meter unit.
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Crankcase Halves Assembly
Install:
Crankshaft (see Crankshaft Installation)
Connecting Rods (see Connecting Rod Installation)
Using a cleaning fluid, clean off any oil or dirt on the mating
surface of the crankcase halves.
Apply liquid gasket to the mating surface of the lower
crankcase half as shown in the fi ...