268
CHAPTER SIX
2. Remove the clamp bolt and remove the shift rod
lever from the shift shaft lever.
141
OIL PAN
3. On 1999-2000 models, loosen the locknut and
back out the adjuster until it clears the centering
plate.
4. Remove the snap ring and washer from the shift
lever shaft.
5A. On 1999-2000 models, perform the following:
a. Withdraw the shift shaft lever, centering plate
and spring out from the inner surface of the
transmission case.
b. Remove the centering plate and spring from
the shift shaft lever.
5B. On 2001 models, withdraw the shift shaft lever,
sleeve and spring out from the inner surface of the
transmission case
NOTE
Proceed with Step 6 only if the compo-
nents require replacement.
6A. On 1999-2000 models, if necessary, remove the
snap ring and washer and remove the shift cam pawl
and spring from the shift shaft lever. The pivot pin is
pressed into the shift shaft lever. If removal is nec-
essary, drive it out with a suitable size punch.
6B. On 2001 models, if necessary, remove the snap
ring and washer and remove the shift cam pawl and
spring from the shift shaft lever.
1.
Gasket
Inspection
2.
Baffle spring
3.
Baffle
1A. On 1999-2000 models, check the shift pawl and
4.
Engine oil drain bolt
centering plate for wear. Replace the pawl if dam-
5.
Oil pan
6.
Bolt
aged. Replace the centering plate if its adjustment
7.
Transmission oil drain
slot is elongated.
bolt
1B. On 2001 models, check the shift pawl for wear.
8.
Plug
Replace the pawl if damaged.
9. O-ring
2. Check the springs for wear or damage. Assem-
ble the pawl and spring on the shift arm pin. If the
spring will not hold the pawl on the cam, replace
ver pivot pin. Secure it with the washer and new
it.
snap ring.
3. Check the shift shaft lever for wear or damage.
1B. On 2001 models, if disassembled, install the
Check the end splines for wear or damage.
shift cam pawl and spring onto the shift shaft. Se-
4. Check the shift rod lever for wear or damage.
cure it with the washer and new snap ring.
Check the internal splines for wear or damage.
2. On 1999-2000 models, install the centering plate
on the shift shaft lever and spring.
3. Install the shift shaft lever assembly into the
Assembly/installation
transmission case.
1A. On 1999-2000 models, if disassembled, install
4A. On 1999-2000 models, align the slot in the cen-
the shift cam pawl and spring onto the shift shaft le-
tering plate with the adjuster.
TRANSMISSION
269
4B. On 2001 models, align the spring with the
Inspection
screw.
5. Refer to the alignment marks made in Step 1 Re-
1. Clean the oil tank, baffle and spring in solvent
moval/Disassembly and install the shift rod lever
and dry thoroughly.
onto the shift shaft lever. Push it on until the bolt
2. Remove all old gasket residue from the oil tank
hole aligns with the shaft lever groove.
and transmission case gasket surfaces.
6. Install the clamp bolt and tighten to the specifi-
3. Inspect the oil pan for cracks or damage. Replace
cation in Table 3.
if necessary.
OIL PAN
Installation
The oil pan mounts onto the bottom of the trans-
mission case. It can be removed with the transmis-
1. Install a new oil tank gasket on the oil pan.
sion mounted in the frame.
2. Install the baffle and baffle spring into the oil
Refer to Figure 141.
6
pan.
3. Install the oil pan onto the bottom of the trans-
Removal
mission case, and secure with the ten bolts.
4. Tighten the oil pan mounting bolts securely in a
1. Drain the engine oil as described in Chapter
crisscross pattern.
Three.
5. If necessary, replace the engine oil filter as de-
2. Drain the transmission oil as described in Chap-
scribed in Chapter Three.
ter Three.
6. Refill the oil pan with new engine oil as de-
3. Remove the ten bolts securing the oil pan to the
scribed in Chapter Three.
transmission case.
4. Lower and remove the oil pan baffle and baffle
7. Refill the transmission with new oil as described
spring from the transmission case.
in Chapter Three.
5. Remove the gasket.
8. Start the engine and check for leaks.
Table 1 TRANSMISSION SPECIFICATIONS
Transmission type
Five-speed, constant mesh
Gear ratios
First
3.21
Second
2.21
Third
1.57
Fourth
1.23
Fifth
1.00
Transmission fluid capacity
Oil change
20-24 U.S. oz. (591-709 ml)
Rebuild (dry)
24 U.S. oz. (709 ml)
Table 2 TRANSMISSION SERVICE SPECIFICATIONS
Item
In.
mm
Countershaft
Runout
0.000-0.003
0.00-0.08
Endplay
None
(continued)
-------------------------------------------------------------------------------------------------------------------------------------------------------------
270
CHAPTER SIX
Table 2 TRANSMISSION SERVICE SPECIFICATIONS (continued)
Item
In.
mm
Countershaft (continued)
First gear
Clearance
0.0003-0.0019
0.008-0.048
End play
0.005-0.0039
0.127-0.099
Second gear
Clearance
0.0003-0.0019
0.008-0.048
End play
0.005-0.0440
0.127-1.118
Third gear
Clearance
0.000-0.0080
0.000-0.203
Fourth gear
Clearance
0.000-0.0080
0.000-0.203
End play
0.005-0.0390
0.127-0.991
Fifth gear
Clearance
0.000-0.0080
0.000-0.203
End play
0.005-0.0040
0.127-0.102
Mainshaft
Runout
0.000-0.003
0.00-0.08
Endplay
None
-
First gear
Clearance
0.000-0.0080
0.000-0.203
Second gear
Clearance
0.000-0.0800
0.000-2.032
Third gear
Clearance
0.0003-0.0019
0.008-0.048
End play
0.0050-0.0420
0.127-1.067
Fourth gear
Clearance
0.0003-0.0019
0.008-0.048
End play
0.0050-0.0310
0.127-0.787
Main drive gear (fifth)
Bearing fit in
transmission case
0.0003-0.0017
0.0076-0.043
Fit in bearing
Tight fit
0.0009
0.023
Loose fit
0.0001
0.0025
Fit on mainshaft
0.0001-0.0009
0.0025-0.023
End play
None
-
Shifter cam assembly
Right edge of middle cam
groove to right support
block distance
1.992-2.002
50.60-50.85
Shifter cam end play
0.0001-0.004
0.0025-0.10
Shifter forks
Shifter fork-to-cam
groove end play
0.0017-0.0019
0.043-0.048
Shifter fork-to-gear
groove end play
0.0010-0.0011
0.025-0.0279
Shift fork finger thickness
0.165
4.19
Side door bearing
Fit in side door
0.0014-0.0001
0.036-0.0025
Fit on countershaft
Tight fit
0.0007
0.018
Loose fit
0.0001
0.0025
Fit on mainshaft
Tight fit
0.0007
0.018
Loose fit
0.0001
0.0025
-------------------------------------------------------------------------------------------------------------------------------------------------------------
TRANSMISSION
271
Table 3 TRANSMISSION TORQUE SPECIFICATIONS
Item
ft.-lb.
in.-lb.
N·m
Clutch cable fitting
-
30-60
3-7
Clutch release
cover screws
-
84-108
9-12
Mainshaft and
countershaft nuts
45-55
-
61-75
Shift rod
Locknuts
20-24
-
27-32
Clamp bolts
18-22
-
24-30
Shift cam support blocks
-
84-108
9-12
Top cover screws
-
84-108
9-12
Transmission main and
countershaft locknuts
at side door
27-33
-
37-45
Transmission case door
1/4 in. fasteners
-
84-108
9-12
6
5/16 in. fasteners
13-16
-
18-22
Transmission drain plug
14-21
-
19-28
Transmission mounting
bolts
30-35
-
41-47
Detent follower bolt (2001)
-
84-108
9-12
Transmission drive
sprocket
Mounting nut*
50
-
68
Lockplate bolts
-
84-108
9-12
* Tighten an additional 30°—not to exceed 45°.
-------------------------------------------------------------------------------------------------------------------------------------------------------------
CHAPTER SEVEN
FUEL, EXHAUST AND
EMISSION CONTROL SYSTEMS
The fuel system consists of the fuel tank, fuel
WARNING
shutoff valve, single side-draft carburetor and air
Gasoline is a known carcinogenic, as
filter housing.
well as an extremely flammable liq-
uid, and must be handled carefully.
The emission control consists of the Evaporative
Wear latex gloves to avoid contact. If
Emission Control System on all California models.
gasoline does contact skin, immedi-
This chapter includes service procedures for all
ately and thoroughly wash the area
parts of the fuel system and the air filter backplate.
with soap and warm water.
Air filter service is covered in Chapter Three.
Specifications and jet sizes are in Tables 1-3 at
the end of the chapter.
CARBURETOR OPERATION
Table 1 lists carburetor jet sizes.
Table 2 lists fuel system torque specifications.
An understanding of the function of each of the
Table 3 lists exhaust system torque specifications.
carburetor components and their relation to one an-
-------------------------------------------------------------------------------------------------------------------------------------------------------------
FUEL, EXHAUST AND EMISSION SYSTEMS
273
1
AIR FILTER
1. Backplate
(international)
2. Grommet (California)
3. Backplate (California)
4. O-ring
5. Gasket
6. Backplate (49-state)
7. Breather hollow bolt
8. Breather hose
9. Gasket
10. Air filter
11. Mounting bracket
12. Torx screws
7
13. Nut clip
14. Enrichment cable
bracket
15. Cable strap
16. Nut
17. Grommet
18. Bolt
19. Screw
20. Trim
21. Cover
22. Seal
other is a valuable aid for pinpointing a source of
the engine next to the horn opens an enrichment
carburetor trouble.
valve, rather than closing a butterfly in the venturi
The carburetor’s purpose is to supply and atomize
area as on some carburetors. In the open position,
fuel and mix it in correct proportions with air that is
the slow jet discharges a stream of fuel into the car-
drawn in through the air intake. At the primary
buretor venturi to enrich the mixture when the en-
throttle opening (idle), a small amount of fuel is si-
gine is cold.
phoned through the pilot jet by the incoming air. As
The accelerator pump circuit reduces engine
the throttle is opened further, the air stream begins
hesitation by injecting a fine spray of fuel into the
to siphon fuel through the main jet and needle jet.
carburetor intake passage during sudden accelera-
The tapered needle increases the effective flow ca-
tion.
pacity of the needle jet as it is lifted, in that it occu-
pies progressively less of the area of the jet. At full
throttle the carburetor venturi is fully open and the
AIR FILTER BACKPLATE
needle is lifted far enough to permit the main jet to
flow at full capacity.
Routine air filter maintenance is described in
The choke circuit is a starting enrichment valve
Chapter Three.
system in which the choke knob on the left side of
Refer to Figure 1.
-------------------------------------------------------------------------------------------------------------------------------------------------------------
274
CHAPTER SEVEN
2
3
Removal
4
1. Remove the air filter cover screw (A, Figure 2)
and remove the cover (B, Figure 2).
2. Remove the Torx screws and bracket (A, Figure
3) from the air filter element.
3. Gently pull the air filter element away from the
backplate and disconnect the two breather hoses
from the hollow bolts on the backplate. Remove the
air filter element (B, Figure 3).
4. Unscrew and remove the breather hollow bolts
(A, Figure 4) securing the backplate to the cylinder
heads.
5A. On California models, pull the backplate (B,
Figure 4) partially away from the cylinder heads
5
and the carburetor, then disconnect the evaporation
emission control clean air inlet hose (Figure 5).
5B. On all other models, pull the backplate (B, Fig-
ure 4) away from the cylinder heads and remove it.
6. Remove the carburetor gasket.
Inspection
1. Inspect the backplate (Figure 6) for damage.
2. On California models, make sure the trap door
swings freely (Figure 7).
3. Make sure the breather hollow bolts and breather
6
hoses (Figure 8) are clear. Clean out if necessary.
Installation
1. Apply a couple dabs of gasket sealer to the new
carburetor gasket and attach it to the backside of the
backplate.
2. Move the backplate into position.
3. On California models, move the backplate part
way into position. Connect the evaporation emis-
-------------------------------------------------------------------------------------------------------------------------------------------------------------
FUEL, EXHAUST AND EMISSION SYSTEMS
275
7
11
sion control clean air inlet hose (Figure 5) to the fit-
8
ting on the backside of the backplate.
4. Position the backplate (B, Figure 4) against the
carburetor and cylinder heads. Make sure the Torx
bolt holes of the gasket and backplate are aligned with
7
the carburetor. Reposition the gasket if necessary.
5. Install the breather hollow bolts (A, Figure 4)
securing the backplate to the cylinder heads.
Tighten to the specification in Table 2.
6. If removed, install a new gasket (Figure 9) onto
the air filter element.
7. Position the element with the flat side facing
down and attach the breather hoses (Figure 10) to
the backside of the element (Figure 11). If an after-
9
market air filter element is being installed, position
it onto the backplate following the manufacturer’s
instructions.
8. Move the element into position (B, Figure 3)
and install the mounting bracket (A, Figure 3) and
the Torx screws. Tighten the Torx screws to the
specification in Table 2.
9. Apply a drop of ThreeBond TB1342 (blue) or an
equivalent threadlocking compound to the cover
screw prior to installation.
10. Inspect the seal ring (Figure 12) on the air filter
cover for hardness or deterioration. Replace if
necessary.
10
11. Install the air filter cover (B, Figure 2) and the
screw (A, Figure 2). Tighten the screw to the speci-
fication in Table 2
CARBURETOR
Removal
1. Remove the air filter and backplate as described
in this chapter.
-------------------------------------------------------------------------------------------------------------------------------------------------------------
276
CHAPTER SEVEN
12
13
2. Remove the fuel tank as described in this chapter.
3. Loosen the locknut (A, Figure 13) and discon-
14
nect the starting enrichment valve cable to the
mounting bracket (B, Figure 13). Move the end of
the cable out of the mounting bracket.
4. There are two different throttle cables. Label the
two cables at the carburetor before disconnecting
them. One is the throttle control cable and the other
is the idle control cable. They are identified as fol-
lows:
a. Throttle control cable: A, Figure 14.
b. Idle control cable: B, Figure 14.
5. At the handlebar, perform the following:
a. Slide the rubber boot off both cables.
15
b. Loosen both control cable adjuster locknuts (A,
Figure 15), then turn the cable adjusters (B)
clockwise as far as possible to increase slack.
6. Disconnect the fuel supply hose (Figure 16)
from the carburetor fitting.
7. Twist and then pull the carburetor off the seal
ring and intake manifold.
8. Disconnect the vacuum hose (Figure 17) from
the carburetor fitting.
9. Disconnect the throttle control cable (A, Figure
18) and the idle control cable (B) from the carbure-
tor cable guide and the throttle wheel.
16
10. Drain the gasoline from the carburetor assem-
bly.
11. Inspect the carburetor seal ring (Figure 19) on
the intake manifold for wear, hardness, cracks or
other damage. Replace if necessary.
12. If necessary, service the intake manifold as de-
scribed under Intake Manifold in this chapter.
13. Insert a clean lint-free shop cloth into the intake
manifold opening.
-------------------------------------------------------------------------------------------------------------------------------------------------------------
FUEL, EXHAUST AND EMISSION SYSTEMS
277
17
21
Installation
18
1. If removed, seat the seal ring (Figure 19) onto
the intake manifold. Make sure it is correctly seated
to avoid a vacuum leak.
7
2. Route the starting enrichment valve cable be-
tween the cylinders and toward its mounting
bracket on the left side.
3. Connect the idle cable (B, Figure 14) to the car-
buretor as follows:
a. The idle cable has the small spring (A, Figure
20) on the end of the cable.
b. Insert the idle cable sheath into the rear cable
bracket guide on the carburetor (B, Figure 20).
c. Attach the end of the idle cable into the throt-
19
tle wheel (C, Figure 20).
4. Connect the throttle cable (A, Figure 14) to the
carburetor as follows:
a. Insert the throttle cable sheath (A, Figure 18)
into the carburetor front cable bracket guide.
b. Attach the end of the throttle cable into the
throttle wheel (C, Figure 18).
5. Operate the hand throttle a few times, making
sure the throttle wheel operates smoothly. Also
check that both cable ends are seated squarely in
their cable bracket guides and in the throttle wheel.
CAUTION
20
The carburetor must fit squarely onto
the intake manifold. If misaligned, it
may damage the intake manifold seal
ring, resulting in a vacuum leak.
6. Align the carburetor squarely with the intake
manifold (Figure 21), then push it into the manifold
until it bottoms. Position the carburetor so that it sits
square and vertical with the manifold.
7. Connect the vacuum hose (Figure 17) onto the
carburetor fitting. Make sure it is seated correctly.
-------------------------------------------------------------------------------------------------------------------------------------------------------------
278
CHAPTER SEVEN
22
CARBURETOR
1. Screw
2. Cover
3. Collar
4. Spring
5. Spring seat
6. Jet needle
7. Vacuum piston
8. Cable sealing cap
9. Cable guide
10. Starting enrichment
cap
11. Spring
12. Starting enrichment
valve
13. Hose clamp
14. Spring
15. Hose
16. Fuel inlet fitting
17. Body
29. Main jet holder
41. Rod
18. Screw
30. Main jet
42. Boot
19. Spring
31. Valve
43. O-ring gasket
20. Screw
32. Float
44. Float bowl
21. Throttle cable bracket
33. Rod
45. Screw
22. Screw and washer
34. Washer
46. Diaphragm
23. Collar
35. Spring
47. Spring
24. Pin
36. Collar
48. O-ring
25. Washer
37. Washer
49. Cover
26. Pilot jet
38. E-clip
50. Washer
27. Float pivot pin
39. Washer
51. Screw
28. Needle jet
40. Pin
52. Lever
-------------------------------------------------------------------------------------------------------------------------------------------------------------
FUEL, EXHAUST AND EMISSION SYSTEMS
279
23
27
8. Slide a new hose clamp over the fuel supply
24
hose, then connect the fuel hose to the hose fitting
on the carburetor (Figure 16).
9. Position the starting enrichment valve cable into
the mounting bracket (B, Figure 13), then tighten
7
the locknut (A, Figure 13) securely.
10. Before installing the fuel tank, recheck the idle
and throttle cable operation. Open and release the
hand throttle. Make sure the carburetor throttle
valve opens and closes smoothly. Check that both
cables are routed properly. If necessary, adjust the
throttle cables as described in Chapter Three.
11. Install the air filter backplate and air filter as de-
scribed in this chapter.
25
12. Install the fuel tank as described in this chapter.
13. Start the engine. Allow it to idle and check for
fuel leaks.
14. With the engine idling in NEUTRAL, turn the
handlebar side-to-side. The idle speed must remain
the same. If the idle speed increases while turning the
handlebars, the cables are installed incorrectly or dam-
aged. Remove the fuel tank and inspect the cables.
Disassembly
Refer to Figure 22.
1. Unscrew and remove the starting enrichment
26
valve and cable (Figure 23).
2. Remove the screw and washer (A, Figure 24) on
the side and the top screw (A, Figure 25) securing
the throttle cable bracket to the carburetor. Remove
the bracket (B, Figure 25).
3. Remove the collar (Figure 26) from the cover.
4. Remove the remaining cover screws (Figure
27). Remove the cover and spring (A, Figure 28).
5. Remove the vacuum piston (B, Figure 28) from
the carburetor housing. Do not damage the jet nee-
Нет комментариевНе стесняйтесь поделиться с нами вашим ценным мнением.
Текст