Sealant - Liquid Gasket, TB1216B [A]: 92104-1064 Liquid Gasket, TB1207B [B]: 92104-2068
NOTE
NOTICE
Do not apply liquid gasket around the crankshaft main bearing inserts and oil passage.
NOTE
Install the drive shaft bearing [A].
Special Tool - Bearing Driver Set: 57001-1129
Face the oil seal side of the bearing to the bottom.
Install the M9 bolts and washers.
L = 113 mm (4.45 in.) [A] L = 100 mm (3.94 in.) [B]
Tighten M9 bolts by following the sequence numbers [1
10].
Torque - Lower Crankcase Bolts (M9): 45 N·m (4.6 kgf·m, 33 ft·lb)
Install the M7 bolts.
L = 50 mm (2.0 in.) [A] L = 45 mm (1.8 in.) [B] Tighten:
Torque - Lower Crankcase Bolts (M7): 20 N·m (2.0 kgf·m, 15 ft·lb)
Replace the M6 bolt washers with new ones.
Install the M6 bolts.
L = 60 mm (2.4 in.) [A] (With Washer) L = 45 mm (1.8 in.) [B] L = 40 mm (1.6 in.) [C]
Install the clamp [D] and washer [E] as shown in the figure.
Tighten:
Torque - Lower Crankcase Bolts (M6): 12 N·m (1.2 kgf·m, 106 in·lb)
Replace the M8 bolt washers with new ones.
Install the M8 bolts [A] and washers.
Install the M7 bolt [B].
Tighten:
Torque - Upper Crankcase Bolts (M8): 27 N·m (2.8 kgf·m, 20 ft·lb) Upper Crankcase Bolt (M7): 20 N·m (2.0 kgf·m, 15 ft·lb)
Wipe up the liquid gasket that seeps out around the crankcase mating surface.
Crankshaft turns freely.
Drive Shaft Bearing Holder [A] Output Shaft Bearing Holder [B]
Turn the flat side [C] of the holders to inside.
Throttle Grip and Cables
Free Play Inspection
Refer to the Throttle Control System Inspection in the Periodic
Maintenance chapter.
Free Play Adjustment
Refer to the Throttle Control System Inspection in the Periodic
Maintenance chapter.
Cable Installation
Install the throttle cables in accordance with the Cable,
...
Clutch Removal
Remove:
Clutch Cover (see Clutch Cover Removal)
Clutch Spring Bolts [A]
Clutch Springs (with Clutch Spring Holders)
Clutch Spring Plate [B]
Pusher [C]
Remove:
Friction Plates (10) [A]
Steel Plates (9) [B]
Spring [C]
Spring Seat [D]
Hold the sub clutch hub [A] ...
Gear Position Switch Output Voltage Inspection
NOTE
Be sure the battery is fully charged.
Turn the ignition switch to OFF.
Remove the fuel tank (see Fuel Tank Removal in the Fuel
System (DFI) chapter).
Disconnect the sidestand switch/gear position switch lead
connector [A].
Connect the measuring adapter [A] between the ...