CHAPTER 3 ENGINE OVERHAUL


ENGINE REMOVAL		3-1
	Preparation for Removal	3-1
	Fuel Tank	3-1
	Air Filter	3-1
	Battery	3-2
	Exhaust Pipes and Mufflers	3-2
	Leads and Couplers	3-3
	Cables and Pipes	3-3
	Footrests Sidestand and Muffler Brackets	3-3
	Engine Removal	3-4
ENGINE DISASSEMBLY		3-5
	Engine-Mounting Bracket and Carburetors	3-5
	Cylinder Heads and Cylinders	3-5
	Piston Pin and Piston	3-6
	Crankcase Covers, Starter Motor, and Oil Pump	3-6
	Flywheel	3-8
	Clutch and Primary Gears	3-9
	Shifter and Oil Strainer	3-9
	Crankcase	3-10
INSPECTION AND REPAIR		3-13
	Cylinder Head Disassembly	3-13
	Cylinder Head	3-14
	Valves, Valve Guides, Valve Seats, and Valve Springs	3-14
	Rocker Arms and Rocker Arm Shafts	3-18
	Camshafts, Cylinder Head Assembly and Cam Sprockets	3-19
	Cylinder Head Assembly	3-19
	Cam Sprocket	3-20
	Cylinder	3-21
	Piston Piston Rings, and Piston Pin	3-21
	Crankcase	3-23
	Bearings and Oil Seals	3-23
	Crankshaft and Connecting Rod	3-23
	Oil Pump	3-27
	Primary Drive	3-27
	Clutch	3-27
	Transmission	3-29
	Starter Drives	3-30
ENGINE ASSEMBLY AND ADJUSTMENT		3-31
	Important Information	3-31
	Left-Side Crankcase	3-32
	Right-Side Crankcase	3-34
	Crankcase Assembly	3-34
	Shifter	3-36
	Front-Cylinder Cam Chain and Drive Gears	3-37
	Clutch	3-38
	Rear-Cylinder Cam Chain and Flywheel	3-40
	Starter Motor and Starter Idle Gear #1	3-41
	Crankcase Covers, Oil Filter, and Oil Strainer	3-42
	Pistons, Cam Chain Guides, and Cylinders	3-43
	Cylinder Head, Rocker Arm, and Camshaft	3-45
	Carburetors and Ignition Coils	3-49
	Mounting the Engine	3-49
MIDDLE GEAR SERVICE		3-52
	Gear Lash Measurement	3-53
	Gear Lash Adjustment	3-53
	Removal	3-54
	Disassembly	3-54
	Inspection	3-55
	Assembly and Adjustment	3-55

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