Yamaha XV19SW(C), XV19W(C), XV19MW(C), XV19CTSW(C), XV19CTW(C), XV19CTMW(C). Service Manual - part 13

STEERING HEAD

4-70

13

Bearing outer race

2

For installation, reverse the removal proce-
dure.

Removing the lower bracket

Order

Job/Parts to remove

Q’ty

Remarks

8

1

3

2

12

11

13

13

10

9

7

6

5

4

LS

LS

LS

T

 

R

1st   52 Nm (5.2 m 

•

 kg, 37 ft 

•

 lb)

2nd  18 Nm (1.8 m 

•

 

kg, 13 ft

 

•

 

Ib)

T

 

R

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

 

R

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

LT

LT

LT

T

 

R

16 Nm (1.6 m 

•

 

kg, 11 ft

 

•

 

Ib)

STEERING HEAD

4-71

EAS23110

REMOVING THE LOWER BRACKET

1. Stand the vehicle on a level surface.

WARNING

EWA13120

Securely support the vehicle so that there is 
no danger of it falling over.

2. Remove:

• Upper ring nut
• Rubber washer
• Lower ring nut “1”
• Lower bracket

WARNING

EWA13730

Securely support the lower bracket so that 
there is no danger of it falling.

NOTE:

Remove the lower ring nut with the steering nut 
wrench “2”.

EAS23120

CHECKING THE STEERING HEAD

1. Wash:

• Bearings
• Bearing races

2. Check:

• Bearings
• Bearing races

Damage/pitting 

→

 Replace.

3. Replace:

• Bearings
• Bearing races

▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼▼▼

a. Remove the bearing races from the steering 

head pipe with a long rod “1” and hammer.

b. Remove the bearing race from the lower 

bracket with a floor chisel “2” and hammer.

c. Install a new dust seal and new bearing rac-

es.

CAUTION:

ECA14270

If the bearing race is not installed properly, 
the steering head pipe could be damaged.

NOTE:

• Always replace the bearings and bearing races 

as a set.

• Whenever the steering head is disassembled, 

replace the dust seal.

▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲▲▲

4. Check:

• Upper bracket
• Lower bracket

(along with the steering stem)
Bends/cracks/damage 

→

 Replace.

EAS23140

INSTALLING THE STEERING HEAD

1. Lubricate:

• Upper bearing
• Lower bearing
• Bearing races

 

Steering nut wrench

90890-01403

Spanner wrench

YU-33975

 

Recommended cleaning solvent

Kerosene

2

1

 

Recommended lubricant

Lithium-soap-based grease

STEERING HEAD

4-72

2. Install:

• Lower ring nut “1”
• Rubber washer “2”
• Upper ring nut “3”
• Lock washer “4”

Refer to “CHECKING AND ADJUSTING 
THE STEERING HEAD” on page 3-25.

3. Install:

• Front brake hose joint “1”
• Front brake hose guide “2”

NOTE:

• Make sure that the projection “a” on the lower 

bracket contacts the side “b” of the front brake 
hose joint “1”.

• Align the projection “c” on the front brake hose 

guide with the hole “d” in the lower bracket.

4. Install:

• Front fork legs
• Upper bracket

Refer to “FRONT FORK” on page 4-60.

1

b

a

d c

2

REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM

4-73

ET1D71001

REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM

Removing the rear shock absorber assembly and swingarm

Order

Job/Parts to remove

Q’ty

Remarks

Rear wheel

Refer to “REAR WHEEL” on page 4-23.

Exhaust pipes

Refer to “ENGINE REMOVAL” on page 5-1.

Brake master cylinder bracket

Refer to “REAR BRAKE” on page 4-43.

Engine mounting nut (rear lower side)

Loosen.
Refer to “ENGINE REMOVAL” on page 5-1.

1

Horn 1 coupler

1

Disconnect.

2

Horn  1

1

3

Passenger footrest (left and right)

2

For XV19S(C)/XV19(C)/XV19M(C) only

4

O

2

 sensor lead guide

1

NOTE:

Pass the O

2

 sensor lead through the guide.

5

Rear brake hose guide

1

6

Self-locking nut/Bolt/Spacer/Washer

1/1/1/1

7

Pivot shaft nut/Washer

1/1

8

Pivot shaft

1

9

Rear shock absorber and swingarm assembly

1

6

2

7

10

9

8

6

T

 

R

59 Nm (5.9 m 

•

 

kg, 43 ft

 

•

 

Ib)

T

 

R

125 Nm (12.5 m 

•

 kg, 90 ft 

•

 lb)

T

 

R

7 Nm (0.7 m

 

•

 kg, 5.1 ft 

•

 Ib)

LS

3

4

3

5

T

 

R

7 Nm (0.7 m

 

•

 kg, 5.1 ft 

•

 Ib)

T

 

R

48 Nm (4.8 m 

•

 

kg, 35 ft

 

•

 

Ib)

LT

1

 

R

48 Nm (4.8 m 

•

 

kg, 35 ft

 

•

 

Ib)

LT

6

REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM

4-74

10

Lower drive belt cover

1

For installation, reverse the removal proce-
dure.

Removing the rear shock absorber assembly and swingarm

Order

Job/Parts to remove

Q’ty

Remarks

6

2

7

10

9

8

6

T

 

R

59 Nm (5.9 m 

•

 

kg, 43 ft

 

•

 

Ib)

T

 

R

125 Nm (12.5 m 

•

 kg, 90 ft 

•

 lb)

T

 

R

7 Nm (0.7 m

 

•

 kg, 5.1 ft 

•

 Ib)

LS

3

4

3

5

T

 

R

7 Nm (0.7 m

 

•

 kg, 5.1 ft 

•

 Ib)

T

 

R

48 Nm (4.8 m 

•

 

kg, 35 ft

 

•

 

Ib)

LT

1

 

R

48 Nm (4.8 m 

•

 

kg, 35 ft

 

•

 

Ib)

LT

6

REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM

4-75

Removing the rear shock absorber and swingarm

Order

Job/Parts to remove

Q’ty

Remarks

1

Self-locking nut/Washer/Bolt

1/2/1

2

Oil seal/Collar/Bushing/Bearing

2/2/1/2

3

Swingarm

1

4

Self-locking nut/Washer/Bolt

1/1/1

5

Connecting arm

2

6

O-ring

4

7

Spacer

1

8

Bushing

4

9

Self-locking nut/Washer/Bolt

1/2/1

10

Rear shock absorber

1

11

Relay arm

1

12

Oil seal/Spacer/Bearing

2/1/1

13

Oil seal/Spacer/Bearing

2/1/2

14

Collar/Oil seal/Spacer/Bearing

2/2/1/2

For installation, reverse the removal proce-
dure.

T

 

R

59 Nm (5.9 m 

•

 

kg, 43 ft

 

•

 

Ib)

2

1

9

4

5

6

6

7

6

6

5

4

12

1

LS

LS

9

LS

LS

LS

12

LS

10

3

8

8

13

13

14

14

11

2

LS

14

14

LS

LS

New

New

 

R

40 Nm (4.0 m 

•

 

kg, 29 ft

 

•

 

Ib)

T

 

R

59 Nm (5.9 m 

•

 

kg, 43 ft

 

•

 

Ib)

REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM

4-76

EAS23180

HANDLING THE REAR SHOCK ABSORBER

WARNING

EWA13740

This rear shock absorber contains highly 
compressed nitrogen gas. Before handling 
the rear shock absorber, read and make sure 
you understand the following information. 
The manufacturer cannot be held responsi-
ble for property damage or personal injury 
that may result from improper handling of 
the rear shock absorber.
• Do not tamper or attempt to open the rear 

shock absorber.

• Do not subject the rear shock absorber to 

an open flame or any other source of high 
heat. High heat can cause an explosion due 
to excessive gas pressure.

• Do not deform or damage the rear shock 

absorber in any way. Rear shock absorber 
damage will result in poor damping perfor-
mance.

EAS23190

DISPOSING OF A REAR SHOCK ABSORBER

1. Gas pressure must be released before dis-

posing of a rear shock absorber. To release 
the gas pressure, drill a 2–3 mm (0.08–0.12 
in) hole through the rear shock absorber at a 
point 15–20 mm (0.59–0.79 in) from its end 
as shown.

WARNING

EWA13760

Wear eye protection to prevent eye damage 
from released gas or metal chips.

ET1D71002

REMOVING THE REAR SHOCK ABSORBER 
ASSEMBLY AND SWINGARM

1. Stand the vehicle on a level surface.

WARNING

EWA13120

Securely support the vehicle so that there is 
no danger of it falling over.

NOTE:

Place the vehicle on a suitable stand so that the 
rear wheel is elevated.

2. Loosen:

• Engine mounting nut (rear lower side)

Refer to “ENGINE REMOVAL” on page 5-1.

NOTE:

Because there is force being exerted on the en-
gine mounting bracket (left and right rear lower 
sides), it is necessary to loosen the engine 
mounting nut (rear lower side) in order to create 
some space between the connecting arms and 
engine bracket before removing the rear shock 
absorber and swingarm.

3. Remove:

• Connecting arm bolt (frame side)

NOTE:

When removing the connecting arm bolt (frame 
side), hold the swingarm so that it does not drop 
down.

4. Measure:

• Swingarm side play
• Swingarm vertical movement

▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼▼▼

a. Measure the tightening torque of the pivot 

shaft nut.

b. Measure the swingarm side play “A” by mov-

ing the swingarm from side to side.

c. If the swingarm side play is out of specifica-

tion, check the spacers, bearings, washers, 
and oil seals.

d. Check the swingarm vertical movement “B” 

by moving the swingarm up and down.
If swingarm vertical movement is not smooth 
or if there is binding, check the spacers, bear-
ings, washers, and oil seals.

T

 

R

.

 

Pivot shaft nut

125 Nm (12.5 m·kg, 90 ft·lb)

 

Swingarm side play (at the end of 
the swingarm)

1.0 mm (0.04 in)

REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM

4-77

▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲▲▲

EAS23240

CHECKING THE REAR SHOCK ABSORBER 
ASSEMBLY

1. Check:

• Rear shock absorber rod

Bends/damage 

→

 Replace the rear shock 

absorber assembly.

• Rear shock absorber

Gas leaks/oil leaks 

→

 Replace the rear shock 

absorber assembly.

• Spring

Damage/wear 

→

 Replace the rear shock ab-

sorber assembly.

• Bushing

Damage/wear 

→

 Replace the rear shock ab-

sorber assembly.

• Spacer

Damage/scratches 

→

 Replace.

• Bolts

Bends/damage/wear 

→

 Replace.

EAS23260

CHECKING THE CONNECTING ARM AND 
RELAY ARM

1. Check:

• Connecting arms
• Relay arm

Damage/wear 

→

 Replace.

2. Check:

• Bearings
• Oil seals

Damage/pitting 

→

 Replace.

3. Check:

• Bushings

Damage/wear 

→

 Replace.

4. Check:

• Spacers
• Collars

Damage/scratches 

→

 Replace.

EAS23360

CHECKING THE SWINGARM

1. Check:

• Swingarm

Bends/cracks/damage 

→

 Replace.

2. Check:

• Pivot shaft

Roll the pivot shaft on a flat surface.
Bends 

→

 Replace.

WARNING

EWA13770

Do not attempt to straighten a bent pivot 
shaft.

3. Wash:

• Pivot shaft
• Bushing
• Washer
• Bearings
• Collars

4. Check:

• Washer
• Oil seals
• Bushing

Damage/wear 

→

 Replace.

• Bearings

Damage/pitting 

→

 Replace.

• Collar

Damage/scratches 

→

 Replace.

ET1D71003

INSTALLING THE RELAY ARM, REAR 
SHOCK ABSORBER ASSEMBLY AND 
CONNECTING ARMS

1. Lubricate:

• Oil seals

A

B

 

Recommended cleaning solvent

Kerosene

 

Recommended lubricant

Lithium-soap-based grease

REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM

4-78

2. Install:

• Bearings “1”, “2”, “3”

(to the relay arm)

• Oil seals “4”, “5”

(to the relay arm)

3. Lubricate:

• Bushings
• Oil seals
• O-rings
• Collar

NOTE:

Apply grease only to the collar between the con-
necting arms and rear shock absorber.

4. Install:

• Bushings “1”

(to connecting arms)

• Spacer “2”

CAUTION:

EC1D71010

When inserting the spacer into the connect-
ing arms and the rear shock absorber, be 
careful not to damage the bushings and O-
rings.

NOTE:

Install the bushings so that the slits “b” in the 
bushings are within the areas shown in the illus-
tration.

5. Install:

• Connecting arms
• Rear shock absorber assembly

(to relay arm)

• Relay arm

(to the swingarm)

NOTE:

Be sure to face the “FWD” mark “a” on the relay 
arm “1” toward the front of the vehicle and to 
face the label “b” on the rear shock absorber “2” 
downward.

 

Installed depth “a”

4.5 mm (0.18 in)

Installed depth “b”

1.0 mm (0.04 in)

Installed depth “c”

6.0 mm (0.24 in)

Installed depth “d”

2.5 mm (0.10 in)

A. Right side
B. Left side

 

Recommended lubricant

Lithium-soap-based grease

c

d

d

c

b

b

a

1

5

4

3

3

2

4

5

4

A

B

4

b

b

a

a

 

Installed depth “a”

4.5 mm (0.18 in)

3. Connecting arm
4. Rear shock absorber
A. Right side
B. Left side
C. 90°

2

a

a

a

a

A

B

3

3

1

1

4

1

3

b

C

C

REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM

4-79

6. Tighten:

• Connecting-arm-to-relay-arm nut

• Rear-shock-absorber-assembly-to-relay-arm 

nut

• Relay-arm-to-swingarm nut

EAS28780

INSTALLING THE SWINGARM

1. Lubricate:

• Bearings
• Collars
• Oil seals
• Pivot shaft

2. Install:

• Bearings “1”

(to swingarm)

3. Install:

• Pivot shaft
• Washer
• Pivot shaft nut

NOTE:

Temporarily tighten the pivot shaft nut.

4. Install:

• Connecting arm bolt (front side)

NOTE:

When installing the connecting arm bolt, hold the 
swingarm so that it does not drop down.

5. Tighten:

• Pivot shaft nut
• Engine mounting nut (rear lower side)
• Connecting arm nut (front side)

6. Adjust:

• Drive belt slack

Refer to “ADJUSTING THE DRIVE BELT 
SLACK” on page 3-24.

T

 

R

.

 

Connecting-arm-to-relay-arm nut

59 Nm (5.9 m·kg, 43 ft·lb)

T

 

R

.

 

Rear-shock-absorber-assembly-
to-relay-arm nut

40 Nm (4.0 m·kg, 29 ft·lb)

T

 

R

.

 

Relay-arm-to-swingarm nut

59 Nm (5.9 m·kg, 43 ft·lb)

 

Recommended lubricant

Lithium-soap-based grease

 

Installed depth “a”

1.0 mm (0.04 in)

2

1

a

b

2. Swingarm
A. Left side
B. Right side

T

 

R

.

 

Pivot shaft nut

125 Nm (12.5 m·kg, 90 ft·lb)

Engine mounting nut (rear lower 
side)

98 Nm (9.8 m·kg, 71 ft·lb)

Connecting arm nut (front side)

59 Nm (5.9 m·kg, 43 ft·lb)

1

1

2

a

a

A

B

BELT DRIVE

4-80

EAS23510

BELT DRIVE

Removing the drive belt and drive pulley

Order

Job/Parts to remove

Q’ty

Remarks

Rear wheel

Refer to “REAR WHEEL” on page 4-23.

Rear shock absorber assembly and swingarm

Refer to “REAR SHOCK ABSORBER AS-
SEMBLY AND SWINGARM” on page 4-73.

1

Rectifier/regulator cover

1

2

Lead cover

1

3

Stator coil coupler

1

Disconnect.

4

Rectifier/regulator coupler

1

Disconnect.

5

Rectifier/regulator

1

6

Drive pulley cover

1

7

Slider

2

8

Dowel pin

2

9

Transfer gear case bracket

1

10

Drive belt

1

11

Drive pulley nut

1

12

Conical spring washer

1

LT

7

8

13

12

11

10

9

6

1

2

4

T

 

R

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

T

 

R

63 Nm (6.3 m 

•

 

kg, 45 ft

 

•

 

Ib)

 

R

53 Nm (5.3 m 

•

 

kg, 38 ft

 

•

 

Ib)

T

 

R

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

(3)

(3)

T

 

R

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

New

7

8

(4)

(6)

5

3

LT

 

R

140 Nm (14.0 m 

•

 kg, 100 ft 

•

 lb)

BELT DRIVE

4-81

13

Drive pulley

1

For installation, reverse the removal proce-
dure.

Removing the drive belt and drive pulley

Order

Job/Parts to remove

Q’ty

Remarks

LT

7

8

13

12

11

10

9

6

1

2

4

T

 

R

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

T

 

R

63 Nm (6.3 m 

•

 

kg, 45 ft

 

•

 

Ib)

 

R

53 Nm (5.3 m 

•

 

kg, 38 ft

 

•

 

Ib)

T

 

R

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

(3)

(3)

T

 

R

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

New

7

8

(4)

(6)

5

3

LT

 

R

140 Nm (14.0 m 

•

 kg, 100 ft 

•

 lb)

BELT DRIVE

4-82

EAS23520

REMOVING THE DRIVE BELT AND DRIVE 
PULLEY

NOTE:

Loosen the drive pulley nut before removing the 
rear wheel.

1. Loosen:

• Drive pulley nut “1”

NOTE:

When loosening the drive pulley nut, press down 
on the brake pedal so the drive pulley does not 
move.

EAS23530

CHECKING THE DRIVE BELT

1. Clean:

• Drive belt

▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼▼▼

a. Wipe the drive belt with a clean cloth.
b. Put the drive belt in a mixture of mild deter-

gent and water. Then, remove any dirt from 
the drive belt.

c. Remove the drive belt from the mixture and 

rinse it off with clean water. Then, let the drive 
belt thoroughly dry.

▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲▲▲

2. Check:

• Drive belt

CAUTION:

ECA14690

• To protect the drive belt from damage, han-

dle it with care.

• The drive belt can not be bent smaller than 

127 mm (5 in) “a”.

• The removed drive belt can not be twisted 

inside out.

3. Check:

• Drive pulley
• Rear wheel pulley

Bent teeth 

→

 Replace the drive belt and pul-

leys as a set.

EAS23540

INSTALLING THE DRIVE BELT AND DRIVE 
PULLEY

1. Install:

• Drive pulley “1”
• Conical spring washer “2”

• Drive pulley nut “3” 

NOTE:

Install the conical spring washer “2” with the 
“OUT” mark “a” facing out.

2. Install:

• Drive belt

CAUTION:

ECA14710

Install the drive belt facing the same way it 
was removed.
Do not twist the drive belt when installing it.

1

New

O U T

a

2

3

1

New

BELT DRIVE

4-83

3. Install:

• Swingarm
• Rear shock absorber

Refer to “REAR SHOCK ABSORBER AS-
SEMBLY AND SWINGARM” on page 4-73.

• Rear wheel

Refer to “REAR WHEEL” on page 4-23.

4. Tighten:

• Drive pulley nut

NOTE:

• When tightening the drive pulley nut, press 

down on the brake pedal so the drive pulley 
does not move.

• Stake the drive pulley nut “1” at a cutout “a” in 

the middle driven shaft.

5. Adjust:

• Drive belt slack

Refer to “ADJUSTING THE DRIVE BELT 
SLACK” on page 3-24.

T

 

R

.

 

Drive pulley nut

140 Nm (14.0 m·kg, 100 ft·lb)

1

a

5

ENGINE

ENGINE REMOVAL

........................................................................................ 5-1

INSTALLING THE SHIFT PEDAL ASSEMBLY......................................... 5-5
CHECKING THE OIL COOLER ................................................................ 5-7
REMOVING THE ENGINE...................................................................... 5-12
INSTALLING THE ENGINE .................................................................... 5-12

CAMSHAFTS

................................................................................................ 5-14

REMOVING THE CYLINDER HEAD COVERS ...................................... 5-21
REMOVING THE ROCKER ARMS, PUSH RODS AND VALVE 

LIFTERS................................................................................................. 5-21

REMOVING THE CAMSHAFTS ............................................................. 5-21
CHECKING THE CAMSHAFTS .............................................................. 5-23
CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS ........ 5-24
CHECKING THE ROCKER ARM BASES............................................... 5-25
CHECKING THE PUSH RODS............................................................... 5-25
CHECKING THE VALVE LIFTERS AND VALVE LIFTER CASES ......... 5-25
CHECKING THE PUSH ROD COVER ................................................... 5-26
CHECKING THE DECOMPRESSION SYSTEM .................................... 5-26
CHECKING THE DECOMPRESSION CAM SPRING ............................ 5-26
CHECKING THE OIL DELIVERY PIPE .................................................. 5-27
INSTALLING THE CAMSHAFTS ............................................................ 5-27
BLEEDING A VALVE LIFTER................................................................. 5-29
INSTALLING THE VALVE LIFTERS....................................................... 5-30
INSTALLING THE ROCKER ARMS AND PUSH RODS ........................ 5-31
INSTALLING THE CYLINDER HEAD COVERS..................................... 5-32
INSTALLING THE SHIFT PEDAL ASSEMBLY....................................... 5-32

CYLINDER HEADS

....................................................................................... 5-33

REMOVING THE CYLINDER HEADS .................................................... 5-35
CHECKING THE CYLINDER HEADS..................................................... 5-35
CHECKING THE OIL PIPE ..................................................................... 5-35
INSTALLING THE CYLINDER HEADS................................................... 5-36

VALVES AND VALVE SPRINGS

................................................................. 5-38

REMOVING THE VALVES ..................................................................... 5-39
CHECKING THE VALVES AND VALVE GUIDES .................................. 5-39
CHECKING THE VALVE SEATS............................................................ 5-41
CHECKING THE VALVE SPRINGS ....................................................... 5-42
INSTALLING THE VALVES .................................................................... 5-43

CYLINDERS AND PISTONS

........................................................................ 5-45

REMOVING THE PISTON ...................................................................... 5-46
CHECKING THE CYLINDERS AND PISTONS ...................................... 5-46
CHECKING THE PISTON RINGS .......................................................... 5-47
CHECKING THE PISTON PINS ............................................................. 5-48
INSTALLING THE PISTONS AND CYLINDERS .................................... 5-48

CLUTCH

........................................................................................................ 5-50

REMOVING THE CLUTCH ..................................................................... 5-60
REMOVING THE PRIMARY DRIVE GEAR ............................................ 5-60
REMOVING THE LEFT BALANCER DRIVE GEAR ............................... 5-60
CHECKING THE FRICTION PLATES .................................................... 5-61
CHECKING THE CLUTCH PLATES....................................................... 5-61
CHECKING THE CLUTCH SPRING PLATE .......................................... 5-61
CHECKING THE CLUTCH HOUSING.................................................... 5-62
CHECKING THE CLUTCH BOSS........................................................... 5-62
CHECKING THE PRESSURE PLATE .................................................... 5-62
CHECKING THE CLUTCH PUSH RODS ............................................... 5-62
CHECKING THE PRIMARY DRIVE GEAR............................................. 5-62
CHECKING THE PRIMARY DRIVEN GEAR .......................................... 5-62
CHECKING THE LEFT BALANCER GEARS ......................................... 5-62
INSTALLING THE LEFT BALANCER DRIVE GEAR.............................. 5-63
INSTALLING THE PRIMARY DRIVE GEAR........................................... 5-64
INSTALLING THE CLUTCH.................................................................... 5-65
DISASSEMBLING THE CLUTCH MASTER CYLINDER ........................ 5-66
CHECKING THE CLUTCH MASTER CYLINDER .................................. 5-66
ASSEMBLING THE CLUTCH MASTER CYLINDER .............................. 5-67
INSTALLING THE CLUTCH MASTER CYLINDER ................................ 5-67
REMOVING THE CLUTCH RELEASE CYLINDER ................................ 5-68
CHECKING THE CLUTCH RELEASE CYLINDER................................. 5-68
ASSEMBLING THE CLUTCH RELEASE CYLINDER ............................ 5-68
INSTALLING THE CLUTCH RELEASE CYLINDER............................... 5-69

SHIFT SHAFT

............................................................................................... 5-70

CHECKING THE SHIFT SHAFT ............................................................. 5-71
CHECKING THE STOPPER LEVER ...................................................... 5-71
INSTALLING THE SHIFT SHAFT ........................................................... 5-71

GENERATOR AND STARTER CLUTCH

..................................................... 5-72

REMOVING THE GENERATOR............................................................. 5-74
REMOVING THE STARTER CLUTCH ................................................... 5-74
CHECKING THE STARTER CLUTCH.................................................... 5-74
CHECKING THE TORQUE LIMITER...................................................... 5-75
INSTALLING THE STARTER CLUTCH.................................................. 5-75
INSTALLING THE GENERATOR ........................................................... 5-75

ELECTRIC STARTER

................................................................................... 5-77

CHECKING THE STARTER MOTOR ..................................................... 5-79
ASSEMBLING THE STARTER MOTOR................................................. 5-80

TRANSFER GEAR CASE

............................................................................. 5-81

REMOVING THE MIDDLE DRIVEN SHAFT........................................... 5-86
CHECKING THE MIDDLE DRIVE........................................................... 5-86
CHECKING THE OIL STRAINER ........................................................... 5-86
CHECKING THE TRANSFER GEAR OIL PUMP ................................... 5-86
CHECKING THE OIL PIPES................................................................... 5-87
ASSEMBLING THE TRANSFER GEAR OIL PUMP ............................... 5-87
INSTALLING THE TRANSFER GEAR CASE......................................... 5-87