Due to friction plate wear and clutch cable stretch over a long period of use, the clutch operation should be checked each day before riding the motorcycle, and must be adjusted in accordance with the Periodic Maintenance Chart.
Inspection
A. Adjuster
B. Clutch Lever Play
Clutch Lever Play
If the play is incorrect, adjust the lever play as follows.
Adjustment
WARNING Excess clutch cable play could prevent clutch disengagement and cause a crash resulting in serious injury or death. When adjusting the clutch cable, be sure the upper end of the outer cable is fully seated in its fitting so that it doesn’t slip into place later and create excessive cable play. |
WARNING The engine and exhaust system get extremely hot during normal operation and can cause serious burns. Never touch a hot engine or an exhaust pipe during clutch adjustment. |
NOTE
DANGER
Exhaust gas contains carbon monoxide, a colorless, odorless poisonous gas. Inhaling carbon monoxide can cause serious brain injury or death.
DO NOT run the engine in enclosed areas. Operate only in a well-ventilated area.
Air Suction Valve Installation
Install the air suction valve so that opening [A] of the reed
faces downward.
Apply a non-permanent locking agent to the threads of
the air suction valve cover bolts [A], and tighten them.
Torque - Air Suction Valve Cover Bolts: 9.8 N·m (1.0 kgf·m,
87 in·lb)
...
Timing Rotor Installation
Install the timing rotor [A] on the crankshaft [B] with their
teeth [C] aligned.
Holding the timing rotor with the flywheel & pulley holder
and tighten the bolt.
Torque - Timing Rotor Bolt: 39 N·m (4.0 kgf·m, 29 ft·lb)
Special Tool - Flywheel & Pulley Holder: 57001-1605
I ...
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 ...