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8. FINAL REDUCTION
8-0
8
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FINAL REDUCTION
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SERVICE INFORMATION........................................................ 8-2
TROUBLESHOOTING.............................................................. 8-2
FINAL REDUCTION DISASSEMBLY....................................... 8-3
FINAL REDUCTION INSPECTION........................................... 8-3
FINAL REDUCTION ASSEMBLY............................................. 8-6
8
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8. FINAL REDUCTION
8-1
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8. FINAL REDUCTION
8-2
SERVICE INFORMATION
Specified Oil: SAE90#
At disassembly: 0.12 liter
At change: 0.1 liter
SPECIAL TOOLS
Bearing remover set, 12mm
Bearing remover set, 15mm
Crankcase assembly collar
Crankcase assembly shaft
Bearing outer driver, 37x40mm
Bearing outer driver, 32x35mm
Bearing driver pilot, 17mm
Bearing driver pilot, 15mm
Bearing driver pilot, 12mm
Bearing outer driver handle A
TROUBLESHOOTING
Engine starts but motorcycle won‘t move
• Damaged transmission
• Seized or burnt transmission
Abnormal noise
• Worn, seized or chipped gears
• Worn bearing
Oil leaks
• Oil level too high
• Worn or damaged oil seal
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8. FINAL REDUCTION
8-3
FINAL REDUCTION DISASSEMBLY
Remove the rear wheel. (14-3)
Remove the left crankcase cover. (7-3)
Remove the clutch/driven pulley. (7-12)
Drain the transmission gear oil into a clean
container.
Remove the transmission case cover
attaching bolts.
Remove the transmission case cover.
Remove the gasket and dowel pins.
Remove the final gear and countershaft.
FINAL REDUCTION INSPECTION
Inspect the countershaft and gear for wear
or damage.
Dowel Pin
Final Gear
Countershaft
Dowel Pin
Countershaft
Driver shift
Driver shift
Bolts
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8. FINAL REDUCTION
8-4
Inspect the final gear and final shaft for
wear, damage or seizure.
Check the left crankcase bearings for
excessive play and inspect the oil seal for
wear or damage.
Inspect the drive shaft and gear for wear or
damage.
Check the transmission case cover bearings
for excessive play and inspect the final
shaft bearing oil seal for wear or damage.
Do not remove the transmission case
cover except for necessary part replacement. When replacing the drive shaft,
also replace the bearing and oil seal.
＊
Final Shaft Bearing
Final Shaft
Drive Shaft Bearing
Countershaft Bearing
Oil Seal
Countershaft
Drive Shaft Bearing
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8. FINAL REDUCTION
8-5
BEARING REPLACEMENT
(Transmission Case Cover)
Remove the transmission case cover
bearings using the bearing remover.
Remove the final shaft oil seal.
Drive new bearings into the transmission
case cover.
BEARING REPLACEMENT (Left
Crankcase Cover)
Remove the drive shaft.
Remove the drive shaft oil seal.
Remove the left crankcase bearings using
the bearing remover.
Drive Shaft Bearing
Bearing Outer Driver, 32x35mm
Bearing Remover Set
Bearing Remover Set, 12mm
Bearing Outer Driver Handle A
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8. FINAL REDUCTION
8-6
Drive new bearings into the left crankcase.
Install a new drive shaft oil seal.
FINAL REDUCTION ASSEMBLY
Install the drive shaft into the left
crankcase.
Install the final gear and final shaft into the
left crankcase.
Drive Shaft
Bearing Outer Driver
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8. FINAL REDUCTION
8-7
Install the countershaft and gear into the left
crankcase.
Install the resin washer onto the countershaft.
Install the dowel pins and a new gasket.
Install the transmission case cover.
Install and tighten the transmission case
cover bolts.
Install the clutch/driven pulley. (7-16)
Install other removed parts in the reverse
order of removal.
Resin Washer
Countershaft
Transmission Case Cover
Bolts
Dowel Pins
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8. FINAL REDUCTION
8-8
After installation, fill the transmission case
with the specified oil.
Specified Gear Oil: SAE90#
Oil Capacity: at disassembly: 0.12 liter
at change: 0.1 liter
Install and tighten the oil check bolt.
Torque: 1.0_ 1.5kg-m
Start the engine and check for oil leaks.
Check the oil level from the oil check bolt
hole and add the specified oil to the proper
level if the oil level is low.
• Place the motorcycle on its main stand
on level ground.
• Check the sealing washer for wear or
damage.
＊
Drain Bolt
Oil Check Bolt Hole/Filler
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