11-10 FINAL DRIVE

Sprocket, Coupling

Engine Sprocket Removal

•Remove:

Speed Sensor Bolt [A] Speed Sensor [B]

Engine Sprocket Cover Bolts [C] Engine Sprocket Cover [D]

•Flatten out the bended washer [A].

•Remove the engine sprocket nut [B] and washer.

NOTE

○When loosening the engine sprocket nut, hold the rear brake on.

•Raise the rear wheel off the ground with the stand.

•Loosen the drive chain (see Drive Chain Slack Adjustment in the Periodic Maintenance chapter).

•Pull the engine sprocket [A] with drive chain [B] off the output shaft [C].

•Disengage the drive chain from the engine sprocket.

Engine Sprocket Installation

•Replace the sprocket washer and axle cotter pin.

•Install the engine sprocket [A] onto the output shaft.

•Apply molybdenum disulfide oil solution to the threads of the output shaft and the seating surface of the engine sprocket nut.

•Tighten:

Torque - Engine Sprocket Nut: 125 N·m (13.0 kgf·m, 92.2 ft·lb)

NOTE

○Tighten the engine sprocket nut while applying the rear brake.

•After torquing the engine sprocket nut, bend [B] the one side of the washer over the nut.

•Adjust the drive chain slack after installing the engine sprocket (see Drive Chain Slack Adjustment in the Periodic Maintenance chapter).

FINAL DRIVE 11-11

Sprocket, Coupling

If the chain guide and engine sprocket cover plate removed, install the as follows.

•Install: Pad [A]

Engine Sprocket Cover Plate [B]

○Insert the groove of the pad into the rib of the engine sprocket cover.

○Apply a non-permanent locking agent to the threads of the engine sprocket cover plate mounting bolts [C].

•Tighten:

Torque - Engine Sprocket Cover Plate Mounting Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)

•Install the chain guide [A].

○Apply a non-permanent locking agent to the threads of the chain guide bolts [B].

•Tighten:

Torque - Chain Guide Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)

•Fit the pins [A] of the engine sprocket cover [B] into the holes [C] of the crankcase.

•Tighten:

Torque - Engine Sprocket Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)

Rear Sprocket Removal

•Remove the rear wheel (see Rear Wheel Removal in the Wheels/Tires chapter).

CAUTION

Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so that the disc does not touch the ground.

•Remove:

Rear Sprocket Nuts [A] Rear Sprocket [B]

11-12 FINAL DRIVE

Sprocket, Coupling

Rear Sprocket Installation

•Install the sprocket facing the tooth number marking [A] outward.

•Tighten:

Torque - Rear Sprocket Nuts: 59 N·m (6.0 kgf·m, 44 ft·lb)

•Install the rear wheel (see Rear Wheel Installation in the Wheels/Tires chapter).

Coupling Installation

•Apply high-temperature grease to the following. Coupling Grease Seal Lips [A]

Coupling Internal Surface [B] Ball Bearing [C]

•Install: Collar [A] Coupling

Coupling Bearing Removal

•Remove: Coupling Grease Seal Circlip [A]

Special Tool - Inside Circlip Pliers: 57001-143

•Remove the bearing [A] by tapping from the wheel side.

Special Tool - Bearing Driver Set [B]: 57001-1129

FINAL DRIVE 11-13

Sprocket, Coupling

Coupling Bearing Installation

•Replace the bearing with a new one.

•Press in the bearing [A] until it is bottomed.

Special Tool - Bearing Driver Set [B]: 57001-1129

•Pack the bearing with high-temperature grease.

•Replace the circlip with a new one.

Special Tool - Inside Circlip Pliers: 57001-143

•Replace the grease seal with a new one.

•Press in the grease seal so that the seal surface is flush with the end of the hole.

○Apply high-temperature grease to the grease seal lips.

Special Tool - Bearing Driver Set: 57001-1129

Coupling Bearing Inspection

Since the coupling bearing is made to extremely close tolerances, the clearance can not normally be measured.

NOTE

○It is not necessary to remove the coupling bearing for inspection. If the bearing is removed, it will need to be replaced with a new one.

•Turn the bearing in the coupling back and forth [A] while checking for plays, roughness or binding.

If the bearing play, roughness or binding is found, replace the bearing.

Coupling Bearing Lubrication

•Pack the bearing with high-temperature grease. Turn the bearing around by hand a few times to make sure the grease is distributed uniformly inside the bearing.

Coupling Damper Inspection

•Remove the rear wheel coupling, and inspect the rubber dampers [A].

•Replace the damper if it appears damaged or deteriorated.