15.38B ... Then install the cover and clutch cable bracket

16.5 Note how the tabs and springs locate 16.8 1.T mark (a), wide spline (b) and

(arrowed) before disassembly locking bolt (C)

Engine, clutch and transmission 2»29

16.9 Install the balancer gear on its shaft

16.12 Check alignments (A) and (B) as described

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		. 'A-i^is
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16.13a Refit the primary gear, timing rotor, bolt and washer ...

9 Apply molybdenum disulphide grease to the inside face of the balancer gear and slide the gear onto its shaft, aligning the wide splines (see illustration).

10. Check that the line next to the T mark on the alternator rotor aligns with notches in the timing inspection hole (see Step 1).

11. If separated, assemble the components of the primary drive gear (see Step 8), align the teeth of the two halves of the gear and lock the halves together (see Section 15).

12. Apply molybdenum disulphide grease to Ihe inside face of the primary drive gear and slide the gear onto the crankshaft, aligning the wide splines. Ensure that the 1 ,T mark on the drive gear aligns with the arrow on the crankcase and that the index line on the drive gear aligns with the index line on the balancer gear (see illustration).

13. Install the timing rotor onto the crankshaft, aligning the wide splines. Apply clean engine oil to the threads of the primary drive gear bolt and refit the bolt and washer finger-tight, then apply clean engine oil to the threads of the balancer gear nut and refit the nut and washer finger-tight (see illustration). Unscrew the bolts locking the halves of the primary drive and balancer gears (see illustration).

14. Lock the two gears together (see Step 2) and tighten the primary drive gear bolt and the balancer gear nut to the torque settings specified at the beginning of this Chapter.

15. Refit the right-hand engine cover (see Section 15).

16. Install the timing inspection plug and the centre plug in the left-hand engine cover.

16.13b ... and the balancer gear nut and washer...

17 Oil pump - removal, inspection and installation

Note: This procedure can be carried out with the engine in the frame. If the engine has been removed, ignore the steps which do not apply.

Removal

1. Remove the clutch and the oil pump drive sprocket, pump sprocket and chain (see Section 15).

2. Unscrew the three bolts securing the pump to the crankcase, then remove the pump, noting how it fits (see illustration).

Inspection

3 Remove the dowels from the pump body then unscrew the bolt securing the pump cover to the body and remove the cover (see illustrations).

16.13c ... then remove the locking bolts (arrowed) from both gears

17.2 Unscrew the three bolts (arrowed) and remove the pump

4 Withdraw the pump driveshaft along with the inner rotor. Retrieve the thrust washer from the pump body if it isn't on the shaft. Note how the pin locates through the pump shaft and in the notches in the inner rotor (see illustration).

17.3a Remove the dowels (A) and the bolt (B)...

17.3b ... and remove the pump cover

17.4 Note the position of the thrust washer (A) and the pin (B)

2*30 Engine, clutch and transmission

17.5 Withdraw the outer rotor, noting position of the punchmark (arrowed)

17.7 Look for scoring and wear, as on this outer rotor

17.8 Measuring inner rotor tip-to-outer rotor clearance

5. 

   17.9 Measuring outer rotor-to-body clearance

   Remove the outer rotor from the pump body (see illustration). Note: The outer rotor is punchmarked to ensure that it is fitted the correct way round. Honda specify that the punchmark should face the pump body but on the bike we stripped down the punchmark faced the pump cover. The important thing is to install the rotor the same way as it was when it was removed so that mated surfaces continue to run together.

6. Clean all the components in solvent.

7. Inspect the pump body and rotors for scoring and wear (see illustration). If any damage, scoring or uneven or excessive wear is evident, renew the pump (individual components are not available). If the engine is being rebuilt, it is advisable to fit a new oil pump as a matter of course.

8. Reassemble the pump components and measure the clearance between the inner rotor tip and the outer rotor with a feeler gauge and compare it that listed in the specifications at the beginning of this Chapter (see illustration). If the clearance measured is greater than that listed, renew the pump.

9. Measure the clearance between the outer rotor and the pump body with a feeler gauge and compare it to that listed in the specifications at the beginning of this Chapter (see illustration). If the clearance measured is greater than that listed, renew the pump.