Exploded View

Exploded View

No.	Fastener	Torque			Remarks
		N·m	kgf·m	ft·lb
1	Engine Sprocket Nut	125	12.7	92		MO
2	Rear Axle Nut	108	11.0	80
3	Rear Sprocket Nuts	59	6.0	44
4	Speed Sensor Bolt	7.8	0.80	69 in·lb		L
5	Speed Sensor Bracket Bolts	9.8	1.0	87 in·lb

G: Apply grease.

HG: Apply high-temperature grease. HO: Apply heavy oil.

L: Apply a non-permanent locking agent. MO: Apply molybdenum disulfide oil solution.

(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10 : 1) R: Replacement Parts

Specifications

Item	Standard	Service Limit
Drive Chain Drive Chain Slack Drive Chain Wear (20-link Length) Standard Chain: Make Type Link	30  40 mm (1.2  1.6 in.)	– – –
	317.5  318.2 mm (12.50  12.53 in.)	323 mm (12.7 in.)
	ENUMA	– – –
	EK520MVXL1	– – –
	114 links	– – –
Sprockets Rear Sprocket Warp	0.4 mm (0.016 in.) or less	0.5 mm (0.020 in.)

Special Tools

Inside Circlip Pliers: 57001-143

Bearing Driver Set: 57001-1129

Drive Chain Slack Inspection

_• Refer to the Drive Chain Slack Inspection in the Periodic Maintenance chapter.

Drive Chain Slack Adjustment

_• Refer to the Drive Chain Slack Adjustment in the Periodic Maintenance chapter.

Wheel Alignment Inspection/Adjustment

_• Refer to the Wheel Alignment Inspection in the Periodic Maintenance chapter.

Drive Chain Wear Inspection

_• Refer to the Drive Chain Wear Inspection in the Periodic Maintenance chapter.

Drive Chain Lubrication

_• Refer to the Drive Chain Lubrication Condition Inspection in the Periodic Maintenance chapter.

Drive Chain Removal

NOTE

○^{Since the drive chain is installed through the swingarm,}

the chain cannot be removed other than by cutting it.

Prepare the new link pin, link plate, grease seals, and tools for rejoining the chain.

_• Using a suitable tool, cut the drive chain by removing the link pins.

Recommended Tool: EK Joint Tool #50

Body [A] Handlebar [B]

Cutting and Riveting Pin [C] For Cutting [D]

For Riveting [E] Plate Holder (a) [F] Plate Holder (b) [G] Gauge [H]

_• Grind [A] the pin head to make it flat.

_• Set the cutting and riveting pin [B] as shown.

_• Screw the pin holder until it touches chain pin.

_• Be sure that the cutting pin hits center of chain pin.

_• Screw the handlebar [A] into body.

_• Turn the pin holder with wrench [B] clockwise to extract

chain pin.

Drive Chain Installation

_• Engage the new drive chain to the old drive chain and pull the end of the old drive chain until they are changing the

position.

_• Remove the old drive chain from the new drive chain.

_• Apply grease to the link pins [A] and grease seals [B] [C].

_• Engage the drive chain on the rear sprocket through the

swingarm.

_• Insert the link pins in the drive chain ends.

_• Install the grease seals [C].

_• Install the link plate so that the mark [D] faces out.

_• Push the link plate by hand or plier to fix it.

_• In case of grease seal chain, be sure to set the grease

seals correctly.

_• Set the plate holder (a) [A] and plate holder (b) [B] on the body.

_• Fit the plate holder (a) to link plate.

_• Turn the pin holder by hand until plate holder (b) touches

the other link plate.

_• Turn the pin holder by wrench clockwise until two pins of link come into groove of plate holder (a).

_• Take off the plate holder (a).

_• Set the plate holder (b) [A] and cutting and riveting pin [B] as shown.

_• Turn the pin holder until riveting pin touches link pin.

_• Turn the wrench clockwise until tip of riveting pin hits of link pin.

_• Rivet it.

_• Same work for the other link pin.

_• After staking, check the staked area of the link pin for cracks.

_• Measure the outside diameter [A] of the link pin and link

plates width [B].

Link Pin Outside Diameter

Standard: 5.7  6.0 mm (0.22  0.24 in.)

Link Plates Outside Width

Standard: 17.25  17.45 mm (0.679  0.687 in.)

If the reading exceeds the specified length, cut and rejoin the chain again.

_• Check:

Movement of the Rollers

_• Adjust the drive chain slack after installing the chain (see Drive Chain Slack Adjustment in the Periodic Mainte-

nance chapter).

Engine Sprocket Removal

_• Remove:

Engine Sprocket Cover Bolts [A]

Engine Sprocket Cover [B]

_• Remove:

Speed Sensor Bracket Bolts [A]

Speed Sensor Bracket [B]

_• Flatten out the bended washer [A].

_• Remove the engine sprocket nut [B] and washer.

NOTE

○^{When loosening the engine sprocket nut, hold the rear}

brake on.

_• Raise the rear wheel off the ground with stand.

_• Remove the axle cotter pin, and loosen the rear axle nut.

_• Loosen the drive chain (see Drive Chain Slack Adjust-

ment in the Periodic Maintenance chapter).

_• Remove the drive chain from the rear sprocket toward the right.

_• Pull the engine sprocket [A] with drive chain [B] off the

output shaft [C].

_• Disengage the drive chain from the engine sprocket.

Engine Sprocket Installation

_• Replace the sprocket washer and axle cotter pin.

_• Install the engine sprocket [A] so that “OUTSIDE” letters

face outward.

_• Apply molybdenum disulfide oil solution to the threads of the output shaft and seating surface of the engine

sprocket nut.

_• After torquing the engine sprocket nut, bend the one side of the washer [B] over the nut.

NOTE

○^{Tighten the engine sprocket nut while applying the rear}

brake.

_• Tighten:

Torque - Engine Sprocket Nut: 125 N·m (12.7 kgf·m, 92 ft·lb) Speed Sensor Bracket Bolts: 9.8 N·m (1.0 kgf·m,

87 in·lb)

_• Install the engine sprocket cover, and tighten the bolts.

_• Adjust the drive chain slack after installing the sprocket

(see Drive Chain Slack Adjustment in the Periodic Main-

tenance chapter).

_• Bend the end of axle cotter pin surely after tightening the axle nut (see Rear Wheel Installation in the Wheels/Tires

chapter).

Rear Sprocket Removal

_• Remove the rear wheel (see Rear Wheel Removal in the Wheels/Tires chapter).

_• Remove the rear sprocket nuts [A].

_• Remove the rear sprocket [B].

Rear Sprocket Installation

_• Install the sprocket facing the tooth number marking [A] outward.

_• Tighten the rear sprocket nuts.

Torque - Rear Sprocket Nuts: 59 N·m (6.0 kgf·m, 44 ft·lb)

_• Install the rear wheel (see Rear Wheel Installation in the Wheels/Tires chapter).

Coupling Installation

_• Apply high-temperature grease to the coupling grease seal lips [A].

_• Apply grease to the coupling internal surface [B].

_• Grease the following. Wheel Flange Portion [A]

O-ring [B]

_• Install the collar [C].

Coupling Bearing Removal

_• Remove: Coupling

Grease Seal Circlip [A]

Special Tool - Inside Circlip Pliers: 57001-143

_• Remove the bearing [A] by tapping from the wheel side.

Special Tool - Bearing Driver Set [B]: 57001-1129

Coupling Bearing Installation

_• Replace the bearing with a new one.

_• Press in the bearing [A] until it is bottomed.

Special Tool - Bearing Driver Set [B]: 57001-1129

_• Replace the circlip with a new one.

Special Tool - Inside Circlip Pliers: 57001-143

_• Replace the grease seal with a new one.

_• Press in the grease seal so that the seal surface is flush

with the end of the hole.

○^{Apply high-temperature grease to the grease seal lips.}

Special Tool - Bearing Driver Set: 57001-1129

Coupling Bearing Inspection

Since the coupling bearing is made to extremely close tolerances, the clearance can not normally be measured.

NOTE

○^{It is not necessary to remove the coupling bearing for}

inspection. If the bearing is removed, it will need to be

replaced with a new one.

_• Turn the bearing in the coupling back and forth [A] while checking for plays, roughness or binding.

If the bearing play, roughness or binding is found, replace the bearing.

_• Examine the bearing seal [B] for tears or leakage.

If the seal is torn or is leaking, replace the bearing.

Coupling Bearing Lubrication

NOTE

○^{Since the coupling bearing is packed with grease and}

sealed, lubrication is not required.

Coupling Damper Inspection

_• Remove the rear wheel coupling, and inspect the rubber dampers [A].

_• Replace the damper if it appears damaged or deterio-

rated.

Sprocket Wear Inspection

_• Visually inspect the engine and rear sprocket teeth for wear and damage.

If the teeth are worn as illustrated, replace the sprocket, and inspect the drive chain wear (see Drive Chain Wear Inspection in the Periodic Maintenance chapter).

Worn Tooth (Engine Sprocket) [A] Worn Tooth (Rear Sprocket) [B] Direction of Rotation [C]

NOTE

○^{If a sprocket requires replacement, the chain is proba-}

bly worn also. When replacing a sprocket, inspect the

chain.

Rear Sprocket Warp Inspection

_• Raise the rear wheel off the ground with stand so that it will turn freely.

_• Set a dial gauge [A] against the rear sprocket [B] near the

teeth as shown, and rotate [C] the rear wheel to measure

the sprocket runout (warp). The difference between the highest and lowest dial gauge readings is the amount of runout (warp).

If the runout exceeds the service limit, replace the rear sprocket.

Rear Sprocket Warp

Standard: 0.4 mm (0.016 in.) or less Service Limit: 0.5 mm (0.020 in.)