Crankcase Assembly

Install the swingarm pivot collars into the lower crankcase.

Apply a light, but thorough, coating of liquid sealant to the crankcase mating surface. Do not apply sealant to the main bearing journal bolt (lower crankcase bolt, 8 mm) area and the oil passage area as shown.

Install the three dowel pins.

Install oil orifices aligning their cut-outs with the groove in the upper crankcase.

COLLARS

OIL ORIFICES

DOWEL PINS

Install the lower crankcase onto the upper crankcase. Clean the new crankcase 8-mrn bolts thoroughly with solvent and blow them dry.

Apply oil to the 8 mm bolt threads and seating surface, and install them.

Install the 10-mm bolt, six 7-mm bolts and two 6-mm bolts.

Make sure the upper and lower crankcases are sealed securely.

From the inside to outside, tighten the lower crankcase 8-mm bolts (main journal bolts) in a crisscross pattern in two or three steps.

Tighten the 10-mm bolt to the specified torque, and then tighten 7-mm bolts and 6-mm bolts.

TORQUE: 10-mm bolt: 39 N-m (4.0 kgf-m, 29 lbf-ft) 7-mm bolt: 18 N-m (1.8 kgf-m, 13 lbf-ft)

7 mm BOLTS

8 mrn BOLTS

3 1 oil 1

Ö '0

6 mm BOLTS

10 mm BOLTS

10 mm BOLTS

ihe sealing wash- Install the upper crankcase five 8-mm bolts and seven er locations are 6 mm bolts with new sealing washers.

indicated on the upper crankcase Tighten the R-mm bolts in a crisscross pattern in two using the "A" Qr ^ mark.

Tighten the 6-mm bolts in a crisscross pattern in two or three steps securely.

6 mm BOLT/ 6 mm BOLTS

SEALING WASHER

6 mm BOLTS

R mm BOLTS/ SEALING WASHERS

R mm BOLTS/ SEALING WASHERS

6 mm BOLT/ 6 mm BOLTS

SEALING WASHER

6 mm BOLTS

Apply o locking ogcnt to the set plate bolt threads. Install the mainshaft bearing set plate with its "OUT SIDE" mark facing.

Install and tighten the bolts to the specified torque. TORQUE: 12 N-m (1.2 kgf-m, 9 Ibf-ft)

Install a new O-ring into the groove in the water hose joint groove.

Install the water hose joint to the cylinder block.

Install and tighten the water hose joint bolls securely.

Install the oil pressure switch (page 19 16). Install the speed sensor (page 19-12).

Install the engine sub-harness and connect the following connectors;

- Speed sensor 3P (Black) connector

- Oil pressure switch connector

- Neutral switch connector

Install the removed parts in the reverse order of removal.

BOLTS

OUT SIDE" MARK

WATER JOINT

SPEED SENSOR " OIL PRESSURE SWITCH

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