Bearing Driver Set: 57001-1129

 

Drive Chain Slack Inspection

• Refer to the Drive Chain Slack Inspection in the Periodic Maintenance chapter.

Drive Chain Slack Adjustment

• Refer to the Drive Chain Slack Adjustment in the Periodic Maintenance chapter.

Wheel Alignment Inspection/Adjustment

• Refer to the Wheel Alignment Inspection in the Periodic Maintenance chapter.

Drive Chain Wear Inspection

• Refer to the Drive Chain Wear Inspection in the Periodic Maintenance chapter.

Drive Chain Lubrication

• Refer to the Drive Chain Lubrication Condition Inspection in the Periodic Maintenance chapter.

Drive Chain Removal

NOTE

○Since the drive chain is installed through the swingarm,

the chain cannot be removed other than by cutting it.

Prepare the new link pin, link plate, grease seals, and tools for rejoining the chain.

• Using a suitable tool, cut the drive chain by removing the link pins.

Recommended Tool: EK Joint Tool #50

CAUTION

Read the Tool Manual before removing.

Body [A] Handlebar [B]

Cutting and Riveting Pin [C] For Cutting [D]

For Riveting [E] Plate Holder (a) [F] Plate Holder (b) [G] Gauge [H]

• Grind [A] the pin head to make it flat.

• Set the cutting and riveting pin [B] as shown.

 

• Screw the pin holder until it touches chain pin.

• Be sure that the cutting pin hits center of chain pin.

 

 

• Screw the handlebar [A] into body.

• Turn the pin holder with wrench [B] clockwise to extract

chain pin.

 

 

Drive Chain Installation

• Engage the new drive chain to the old drive chain and pull the end of the old drive chain until they are changing the

position.

• Remove the old drive chain from the new drive chain.

• Apply grease to the link pins [A] and grease seals [B] [C].

• Engage the drive chain on the rear sprocket through the

swingarm.

• Insert the link pins in the drive chain ends.

• Install the grease seals [C].

• Install the link plate so that the mark [D] faces out.

• Push the link plate by hand or plier to fix it.

• In case of grease seal chain, be sure to set the grease

seals correctly.

• Set the plate holder (a) [A] and plate holder (b) [B] on the body.

 

 

• Fit the plate holder (a) to link plate.

• Turn the pin holder by hand until plate holder (b) touches

the other link plate.

 

 

• Turn the pin holder by wrench clockwise until two pins of link come into groove of plate holder (a).

• Take off the plate holder (a).

 

• Set the plate holder (b) [A] and cutting and riveting pin [B] as shown.

 

• Turn the pin holder until riveting pin touches link pin.

 

 

• Turn the wrench clockwise until tip of riveting pin hits of link pin.

• Rivet it.

• Same work for the other link pin.

 

 

• After staking, check the staked area of the link pin for cracks.

• Measure the outside diameter [A] of the link pin and link

plates width [B].

Link Pin Outside Diameter

Standard: 5.7 ~ 6.0 mm (0.22 ~ 0.24 in.)

Link Plates Outside Width

Standard: 17.25 ~ 17.45 mm (0.679 ~ 0.687 in.)

If the reading exceeds the specified length, cut and rejoin the chain again.

• Check:

Movement of the Rollers

• Adjust the drive chain slack after installing the chain (see Drive Chain Slack Adjustment in the Periodic Mainte-

nance chapter).

 

Engine Sprocket Removal

• Remove:

Engine Sprocket Cover Bolts [A]

Engine Sprocket Cover [B]

 

• Remove:

Speed Sensor Bracket Bolts [A]

Speed Sensor Bracket [B]

 

 

• 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 stand.

• Remove the axle cotter pin, and loosen the rear axle nut.

• Loosen the drive chain (see Drive Chain Slack Adjust-

ment in the Periodic Maintenance chapter).

• Remove the drive chain from the rear sprocket toward the right.

• 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] so that “OUTSIDE” letters

face outward.

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

sprocket nut.

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

NOTE

○Tighten the engine sprocket nut while applying the rear

brake.

• Tighten:

Torque - Engine Sprocket Nut: 125 N·m (12.7 kgf·m, 92 ft·lb) Speed Sensor Bracket Bolts: 9.8 N·m (1.0 kgf·m,

87 in·lb)

• Install the engine sprocket cover, and tighten the bolts.

• Adjust the drive chain slack after installing the sprocket

(see Drive Chain Slack Adjustment in the Periodic Main-

tenance chapter).

• Bend the end of axle cotter pin surely after tightening the axle nut (see Rear Wheel Installation in the Wheels/Tires

chapter).

Rear Sprocket Removal

CAUTION

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

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

• Remove the rear sprocket nuts [A].

• Remove the rear sprocket [B].

Rear Sprocket Installation

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

• Tighten the rear sprocket nuts.

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 coupling grease seal lips [A].

• Apply grease to the coupling internal surface [B].

 

 

• Grease the following. Wheel Flange Portion [A]

O-ring [B]

• Install the collar [C].

 

 

Coupling Bearing Removal

• Remove: Coupling

Grease Seal Circlip [A]