Installation

12. If removed, install the pin in the end of the selector drum. Install the selector cam, locating the pin in the recess in the back of the cam (see illustration 19.11). Clean the threads of the centre bolt, then apply a suitable non-permanent thread-locking compound. Install the bolt and tighten it to the specified torque setting.

13. Fit the stopper arm assembly onto the shoulder on the fixing bolt and screw the bolt into the casing, making sure the ends of the return spring are located correctly over the stopper arm and against the casing (see illustration 19.5a). Position the stopper arm roller in the neutral detent on the selector cam and ensure that the stopper arm is free to move and is returned by the pressure of the spring (see illustration).

14. Check that the gearchange shaft return spring is properly positioned and that the circlip is in its groove. Slide the washer onto the shaft. Lightly grease the inside of the gearchange shaft oil seal in the left-hand side of the engine and slide the shaft into place from the right-hand side (see illustration).

15. Locate the selector arm pawls onto the pins on the selector cam and the ends of the return spring onto each side of the locating pin (see illustration 19.4a).

16. Align the gearchange lever with the punchmark on the gearchange shaft and refit the lever. Tighten the lever pinch bolt to the

torque setting specified at the beginning of

this Chapter.

17 Install the clutch (see Section 15).

_I

20 Crankcase halves -

separation and reassembly

Note 1: To separate the crankcase halves, the engine must be removed from the frame. Note 2: If the crankcases are being separated to inspect the crankshaft without removing it, or to inspect or remove the transmission shafts, the cylinder head can remain in place. However, if removal of the crankshaft or pistons and connecting rods is intended, full disassembly of the top-end is necessary. The gearchange mechanism external components can remain in place unless the selector drum and forks are being removed.

Separation

1. To access the pistons, connecting rods, camchain and guides, crankshaft, balancer shaft, bearings, transmission shafts and the selector drum and forks, the crankcase must be split into two parts.

2. Remove the engine from the frame (see Section 5). Before the crankcase can be split the following components must be removed:

1. Valve cover (Section 7) (see Note 2).

2. Camshafts (Section 9) (see Note 2).

3. Cylinder head (Section 10) (see Note 2).

4. Starter motor (Chapter 9).

19.11 Cam locating pin (a) and locating recess (b)

19.13 Position the stopper arm roller in the neutral detent

19.14 Install shaft with washer (a) and locate return spring (b) on pin (c)

2«34 Engine, clutch and transmission

5. 

   Alternator (Chapter 9).

6. Clutch (Section 15).

7. Oil pump (Section 17). h) Water pump (Chapter 3).

i) Primary drive and balancer gear

(Section 16). j) Oil sump (Section 18). k) Gearchange mechanism external

components (Section 19) (see Note 2).

3. Unscrew the five 6 mm upper crankcase bolts (see illustration). Unscrew the bolts evenly, a little at a time in a criss-cross pattern until they are finger-tight, then remove them, noting their different lengths. Note: As each bolt is removed, store it in its relative position in a cardboard template of the crankcase halves. This will ensure all bolts are installed in their correct locations on reassembly. Sealing washers are fitted with bolts whose locations are identified by a triangle cast into the crankcase (see illustration). Discard the washers as new ones should be fitted on reassembly.

4. Unscrew the two 8 mm upper crankcase bolts evenly and a little at a time until they are finger-tight, then remove them and place them in the template. Discard the sealing washers as new ones should be fitted on reassembly (see illus­tration 20.3a).

5. Unscrew the single 10 mm upper crankcase bolt from the rear left-hand corner of the crankcase (see illustration 20.3a).

6. Turn the engine upside down. Note: // the cylinder head has been removed, rest the engine on a block of wood to avoid damaging the camchain and camchain guides.

7. Unscrew the eight 6 mm lower crankcase bolts evenly, a little at a time in a criss-cross