photo) is available through K&L Supply (P/N: YM-
91042).

TIP:

Depending on the position of the crankshaft, the web-
bing of the crank or connecting rod #4 may overlap
the primary drive gear, making it difficult, if not impos-
sible, to remove the clutch basket/primary drive gear.
If so, rotate the engine to eliminate the overlap.

PAGE 8 of 18

DO NOT USE POWER TOOLS TO LOOSEN THE CLUTCH HUB NUT,
THIS MODEL IS EQUIPPED WITH A SLIPPER CLUTCH AND DAN-
AGE WILL RESULT. USE AN APPROPRIATE CLUTCH HOLDER

AND HAND TOOLS.

TIP (Continued):

a. Check to see if the crankshaft web or connecting
rod is in front of the primary driven gear.

b. If itis, rotate the crankshaft to move the crank web
or connecting rod out of the way before continu-

ing.

26. Remove the oil pump chain guide, starter idler
gear, and shift shaft. Note that the shift shaft has
an e-clip located on the opposite side of the en-
gine. Take care to watch for the washer from the
shift shaft, it may stick to the crankcase. Keep this
washer for reuse upon assembly.

PAGE 9 of 18

27. Remove the oil pump drive chain from the oil
pump gear. Remove the 3 bolts from the oil
pump assembly and the 3 bolts from the oil pipes
shown, then remove the oil pump with the pipes
attached as an assembly. Take care to not lose
the oil pump dowel pins and watch for O-rings
around the oil delivery pipes that may stick in the
crankcase when removing them.

TIP:
Remove the oil pump chain “a” from oil pump sprocket
before oil pump ‘A’ removal.

28. Separate the case halves by loosening, then re-
moving the 40 fasteners in the order shown. Gen-
tly use a soft-faced mallet on the reinforced areas
of the crankcase to release the 2 halves evenly.
Do not use excessive force. Lift the lower portion
of the crankcase off taking care to not dislodge
any of the crank journal or counter balancer bear-
ings out of place. If any of the bearings come out,
be careful to reinstall them into the correct posi-
tions on the case half.

TIP:

e Loosen each bolt % of a turn at a time, in stages
and in a crisscross pattern. After all of the bolts
are fully loosened, remove them.

e Loosen the bolts in the proper sequence as
shown.

e The numbers embossed on the crankcase indi-
cate the crankcase tightening sequence.

NOTICE:
Tap on one side of the crankcase with a soft-face

hammer. Tap only on reinforced portions of the
crankcase, not on the crankcase mating surfac-
es. Work slowly and carefully and make sure the
crankcase halves separate evenly.

PAGE 10 of 18

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DISCARD ALL BOLTS WITHIN THE RECTANGLE AREA

29. Remove the countershaft and crankcase dowel
pins, ‘A.”” Remove the drive axle assembly “B.”

30. Remove the retainers that cover the shift drum
and shift fork shafts and remove the shift drum,
shift forks shafts, and shift forks. Take note of the
orientation and position of the forks for reassem-
bly. There is a spring located inside of the shift
fork shaft on both ends; do not lose these. Next,
remove the 3 bolts retaining the transmission
main shaft.

31. Remove shift drum retainer ‘A’ and “B”

32. Remove:
e Shift fork guide bars
¢ — Shift fork-L

6 * Shift fork-R
¢ Shift drum assembly
e Shift fork-C

PAGE 11 of 18
33. Remove the main axle assembly.

TIP:

e Insert two bolts (M6) ‘A’ into the main axle assem-
bly bearing housing “B.”

e Tighten the bolts until they contact the crankcase
surface.

e Continue tightening the bolts until the main axle
assembly comes free from the upper crankcase.

¢ Do NOT use power tools to tighten.

34. Replace the main assembly and drive axle in the
Kit part. Then, assemble by referring to the Ser-
vice Manual and the following steps.

NOTICE:

When a bolt with LOCTITE® is removed, the LOC-
TITE remains in the internal threads. Clean up the

internal thread using a tap.
Use a new bolt and apply LOCTITE to the bolt

threads.

PAGE 12 of 18

CLEAN UP LOCTITE RESIDUE USING A TAP

Install the Drive Axle Assembly

35. Apply engine oil on the outer surfaces of the main
axle bearing. Then, insert the main axle into the
crankcase axle assembly bearing housing.

36. Perform the following:
¢ Insert three bolts (M6 20mm) ‘A’ into the main axle
assembly bearing housing.
@ ¢ Tighten each bolt 1/2 of a turn at a time until the
bearing housing contacts to crankcase surface.
During this procedure, check if the shaft can be
turned smoothly.
¢ Remove the three bolts and tighten the three new
@ bolts with LOCTITE 12 Nm (1.2m-kgf, 8.7 ft-Ibf).

PAGE 13 of 18

e After tighten three bolts, check if the shaft can
be turned smoothly.
If it is not smooth, remove the shaft and tap
the bearing ”B” to insert it into the crankcase
properly. Repeat the procedure.

e Reinstall the shift forks after installing the main
axle but before installing the drive (counter-
shaft) axle.

37. Make sure the projection “a” on the drive as-
sembly is inserted into the slot in the crank-
case.

PAGE 14 of 18

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ENGINE AND UNIT REASSEMBLY TIPS

Assemble the engine in the reverse order of disas-
sembly using the Service Manual (LIT-11616-28-52)
as a guide. Read and understand the following tips for
reassembly prior to beginning assembly.

CRANKCASE
e¢ When installing the shift drum into the crankcas-
es, be cautious inserting the indexed end of the
shaft into the gear position sensor. Do not force
© the shift drum into position.
e¢ Double check that all main journal and counter
balancer bearings are in their correct locations

and add a light coating of oil to the bearing sur-

34
faces before assembling the crankcase halves. rm y*
¢ Apply sealant only in the areas designated in the ia (O11 O13
above right diagram. 3120 1410635,
sig “03, Gs],
Do not apply sealant to the areas where it is pos-

Creshsase Bedis “9° 6°19"
‘tat 20 Men (2.0 re egt, 14 tbh)
“Qreek: 19 Men £18 aeedagt 11 Pelt.
‘We: Gpecitiod angie 75°

sible to block an oil passage.

e When installing the crankcase bolts, install and
torque the bolts in the correct order and to the VA
correct torque specification. Oe 572136 | a

|

Crarhcese baals “He
10 Nem {1.0 er lagt, 7.2 tA)

CLUTCH
e When assembling the clutch, be aware that the

© outermost 3 plates (2 fiber and one steel) and in-
nermost 1 fiber plate are different than the others. \

e Verify the oil pump gear is properly aligned to the
primary gear. Make sure the projections “a” of the \

oil pump drive sprocket fit into the indentations “b” i

on the clutch housing “1.”

s /
| /
(6 =@) [(S[10 Nm (1.0m - kgf, 7.2 ft-Ibf)

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PAGE 15 0f 18

e When installing the clutch housing assembly, turn
the crankshaft so the crankshaft web “c” is not vis-
ible if it was moved after step 25.

e Verify that the the oil pump chain is correctly in-
stalled before tightening the clutch hub nut. Do
this BEFORE installing the oil pan so the oil pump
chain can be visually inspected and verified.

¢ Do not reuse the clutch hub nut. Torque all fasten-
ers to specification.