Service Limit: 83.10 mm (3.2716 in.)

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▷ Содержание

⇐ ПредыдущаяСтр 18 из 32Следующая ⇒

Piston Wear

• Measure the outside diameter [A] of each piston 18 mm (0.7087 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 pis- ton.

Piston Diameter

Standard: 82.969 ~ 82.984 mm (3.2665 ~ 3.2671 in.)

Service Limit: 82.82 mm (3.2606 in.)

Piston Ring, Piston Ring Groove Wear

• Check for uneven groove wear by inspecting the ring seat- ing.

The rings should fit perfectly parallel to groove surfaces. If not, replace the piston and all the piston rings.

• With the piston rings in their grooves, make several mea-

surements with a thickness gauge [A] to determine piston

ring/groove clearance.

Piston Ring/Groove Clearance Top

Standard: 0.03 ~ 0.07 mm (0.0012 ~ 0.0028 in.)

Service Limit: 0.17 mm (0.0067 in.) Second

Standard: 0.02 ~ 0.06 mm (0.0008 ~ 0.0024 in.)

Service Limit: 0.16 mm (0.0063 in.)

Piston Ring Groove Width

• Measure the piston ring groove width.

○Use a vernier caliper at several points around the piston.

Piston Ring Groove Width Top [A]

Standard: 0.92 ~ 0.94 mm (0.0362 ~ 0.0370 in.)

Service Limit: 1.02 mm (0.040 in.) Second [B]

Standard: 1.01 ~ 1.03 mm (0.0398 ~ 0.0406 in.)

Service Limit: 1.11 mm (0.044 in.)

If the width of any of the two grooves is wider than the service limit at any point, replace the piston.

Piston Ring Thickness

• Measure the piston ring thickness.

○Use the micrometer to measure at several points around

the ring.

Piston Ring Thickness Top [A]

Standard: 0.87 ~ 0.89 mm (0.0342 ~ 0.0350 in.)

Service Limit: 0.80 mm (0.031 in.) Second [B]

Standard: 0.97 ~ 0.99 mm (0.0382 ~ 0.0390 in.)

Service Limit: 0.90 mm (0.035 in.)

If any of the measurements is less than the service limit on either of the rings, replace all the rings.

NOTE

○When using new rings in a used piston, check for un-

even groove wear. The rings should fit perfectly parallel

to the groove sides. If not, replace the piston.

Piston Ring End Gap

• Place the piston ring [A] inside the cylinder, using the pis- ton to locate the ring squarely in place. Set it close to the

bottom of the cylinder, where cylinder wear is low.

• Measure the gap [B] between the ends of the ring with a thickness gauge.

Piston Ring End Gap Top

Standard: 0.25 ~ 0.40 mm (0.0098 ~ 0.0157 in.)

Service Limit: 0.7 mm (0.028 in.) Second

Standard: 0.40 ~ 0.55 mm (0.0157 ~ 0.0217 in.)

Service Limit: 0.8 mm (0.031 in.)

If the end gap of either ring is greater than the service limit, replace all the rings.

Throttle Body Holder

Throttle Body Holder Installation

• Be sure to install the O-rings [A].

• Install the clamps [B] as shown and so that their projec-

tions fit [C] on the holes of the holders.

○Be sure that the clamp bolt heads [D] face outwards.

• Tighten:

Torque - Throttle Body Holder Bolts [E]: 12 N·m (1.2 kgf·m, 106 in·lb)

Muffler

Muffler Body Removal

WARNING

To avoid a serious burn, do not remove the muffler when the engine is still hot. Wait until the muffler cool down.

• Remove:

Right Frame Cover (see Frame Cover Removal in the

Frame chapter)

• Remove the bolts and lift up the right footpeg stay [A].

• Remove the muffler body mounting bolts [A] and nut, and pull the muffler body [B] backward.

Exhaust Pipe Removal

• Remove:

Lower Fairings (see Lower Fairing Removal in the Frame

chapter)

Center Fairings (see Center Fairing Removal in the Frame chapter)

Muffler Body Clamp Bolt [A]

Exhaust Pipe Manifold Holder Nuts [B] Exhaust Pipe [C]

Gaskets

Muffler

Muffler Body and Exhaust Pipe Installation

• Replace the exhaust pipe gaskets [A] and muffler body connection gasket [B] with new ones and install them.

○Install the muffler body connection gasket until it is bot-

tomed so that the chamfer side [C] feces muffler body [D].

• Install:

Muffler Body

Exhaust Pipe [E]

• Tighten:

Torque - Exhaust Pipe Manifold Holder Nut [F]: 17 N·m (1.7 kgf·m, 12 ft·lb)

Muffler Body Mounting Bolts (Front and Rear) [G]: 20 N·m (2.0 kgf·m, 15 ft·lb)

• Tighten the muffler body clamp bolt [H].

○Install the muffler body clamp bolt as shown.

• Thoroughly warm up the engine, wait until the engine

cools down, and retighten all the bolts and nuts.

Clutch

Table of Contents

Exploded View........................................................................................................................ 6-2

Specifications......................................................................................................................... 6-4

Special Tool and Sealant........................................................................................................ 6-5

Clutch Lever and Cable.......................................................................................................... 6-6

Clutch Lever Free Play Inspection.................................................................................... 6-6

Clutch Lever Free Play Adjustment.................................................................................. 6-6

Clutch Cable Removal...................................................................................................... 6-6

Clutch Cable Installation................................................................................................... 6-6

Clutch Cable Lubrication................................................................................................... 6-6

Clutch Lever Installation.................................................................................................... 6-7

Clutch Lever Adjustment................................................................................................... 6-7 6

Clutch Cover........................................................................................................................... 6-8

Clutch Cover Removal...................................................................................................... 6-8

Clutch Cover Installation................................................................................................... 6-8

Release Shaft Removal.................................................................................................... 6-9

Release Shaft Installation................................................................................................. 6-9

Clutch Cover Disassembly................................................................................................ 6-9

Clutch Cover Assembly..................................................................................................... 6-10

Clutch..................................................................................................................................... 6-11

Clutch Removal................................................................................................................. 6-11

Clutch Installation.............................................................................................................. 6-11

Clutch Plate, Wear, Damage Inspection........................................................................... 6-13

Clutch Plate Warp Inspection............................................................................................ 6-14

Clutch Spring Free Length Measurement......................................................................... 6-14

Clutch Housing Finger Inspection..................................................................................... 6-14

Clutch Housing Spline Inspection..................................................................................... 6-14

Exploded View

Exploded View

CL: Apply cable lubricant. EO: Apply engine oil.

G: Apply grease.

HG: Apply high-temperature grease.

L: Apply a non-permanent locking agent. Lh: Left-hand threads

M: Apply molybdenum disulfide grease. R: Replacement Parts

S: Follow the specified tightening sequence. W: Apply water.

Specifications

Special Tool and Sealant

Clutch Holder: 57001-1243

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