1. Remove:
Piston pin clips "1"
Piston pin "2"
Piston "3"
CAUTION: Do not use a hammer to drive the piston pin out. |
NOTE:
Before removing the piston pin clip, cover the crankcase opening with a clean rag to prevent the piston pin clip from falling into the crankcase.
Before removing the piston pin, deburr the piston pin clip groove and the piston pin bore area.
If both areas are deburred and the piston
pin is still difficult to remove, remove it with the
piston pin puller set "4".
2. Remove:
Top ring
2nd ring
Oil ring
NOTE:
When removing a piston ring, open the end gap with your fingers and lift the other side of the ring over the piston crown.
Cable routing
Front brake light switch lead
Right handlebar switch lead
Throttle cable
Main switch
Clutch cable
Clutch switch lead
Left handlebar switch lead
Sub-wire harness
Horn
Speed sensor lead
Front brake hose
Main switch lead
Left headlight assembly lead
Right headlight asse ...
Assembling the water pump
1. Install:
Water pump seal "1"
(into the water pump housing "2")
CAUTION:Never lubricate the water pump seal
surface
with oil or grease.
NOTE:
Install the water pump seal with the special
tools.
Install the water pump seal with the special
tools to the specifi ...
Disassembling the front fork legs
The following procedure applies to both of the
front fork legs.
1. Remove:
Rubber cap
Clip "1"
Front fork cap "2"
(with O-ring)
Fork spring
NOTE:
Push the front fork cap in the direction of the arrow
shown in the illustration to remove the clip.
2. Drain:
Fork oil
NOTE ...