Note
For clarity, the figures show the engine removed from the frame.
Loosen and remove the water pump cover (12) fixing screws (13) to the generator cover (16).
Remove the water pump cover (12).
Clean the pump housing of any scale. Check the bearings wear by turning the impeller shaft (10); in case of excessive clearance, it is necessary to replace them by operating as follows.
Remove the circlip (3) on the impeller shaft.
Slide off the rotor (10) with the sealing ring (9) from the outside.
Recover the ceramic washer - seal unit (8) placed on the internal side.
Undo and remove the screws (1) with the washer (2).
Working from the generator cover (16) internal side, use a suitable punch to press on the inner race of end bearing (5) until it can be extracted from the cover.
Use the same technique to remove the other bearing (6).
Remove the inner spacer (7).
Check the condition of the components of the mechanical seal: there should be no signs of deformation, cracking, or excessive wear. In the case of damage, both components must be renewed.
Disassembly of the clutch cover
Remove the plug (14) and its o-ring (13), the plug (17) and its o-ring (15)
from the cover.
Undo the fixing screw (16) of the inner cover (19).
Remove the inner cover (6) and soundproofing panel (18).
Remove the circlip (10) and withdraw the shim (9) and the sealing ring (8).
The dri ...
Gearchange mechanism
Return spring
Washer
Special screw
Gear pawl assembly
Interlock plunger holder
Sealing washer
Detent ball spring
Ball
Circlip
Selector claw return spring
Shim washer
Ring
Nut
Selector drum control fork
Gearchange lever pin
Shaft with gearchange lever arm
Gearch ...
Checking engine oil level
Check the engine oil level through the sight glass (1) on the
clutch cover. When checking oil level, the motorcycle should
be perfectly upright and the engine cold. The oil level should
be between the two marks next to the sight glass. If level is
low, top up with shell advance ultra 4 engine oi ...