SAFETY FIRST: Protective gloves and eyewear are recommended at this point.
Right Side Engine Component Removal
Remove the clutch. See the Clutch topic for more information.
Loosen the shift drum stopper bolt with a 10 mm socket.
Remove the bolt, shift drum stopper and spring..
Remove the shift drum bolt using a 5 mm Allen socket.
Remove the shift drum star.
Remove the shift shaft by pulling it out.
Oil Pump
Remove the three screws that hold the oil pump in place using a #3 Phillips head screwdriver. You may need to use a hand held impact driver to loosen the three screws.
Pull off the oil pump.
Oil Pump and Primary Drive Gears
Flatten the locking tab washer with a hammer and drift.
Remove the primary drive gear nut on the end of the crankshaft using a 32 mm socket.
Remove the oil pump drive gear.
Remove the primary drive gear.
Remove the key and washer.
Balancer Weight
Flatten the locking tab washer.
Remove the front balancer nut using a 24 mm wrench.
Remove the balancer.
Remove the thrust washer behind it.
Right Side Engine Component Installation
Shift Mechanism
Install the shift drum star, making sure to align the pin in the shift drum with the hole in the shift drum star.
Torque the Allen bolt to specification using a 5 mm Allen socket.
Shift drum star Allen bolt torque: 12 N-m or 8.5 ft-lb
Install the shift drum stopper and spring and tighten the bolt securely with a 10 mm socket.
Install the shift shaft by sliding it into position.
Install the front balancer weight washer.
Install the front balancer weight, making sure to align the small dot (at the top of the weight, not the larger dot at the bottom) with the notch in the end of one of the splines of the balancer shaft..
Note: Failure to align the timing marks will cause the engine to vibrate excessively.
Install a new locking tab washer and the front balancer shaft nut. Make sure the tab on the washer fits into the hole in the balancer weight and bend the washer up against one of the flats of the nut.
Torque the nut to specification using a 24 mm wrench.
Front balancer shaft nut torque: 44 N-m or 33 ft-lb
Install the washer on the end of the crankshaft and place the key in the keyway. Slide the primary drive gear on the crankshaft.
Install the oil pump gear on the crankshaft.
Place a new locking tab washer on the crankshaft, making sure to align the tab with the keyway slot in the gear.
Install the nut and torque it to specification using a 32 mm socket. Bend the washer up against one of the flats of the nut.
Primary drive gear nut torque: 120 N-m or 87 ft-lb
Install the clutch. See the Clutch topic for more information.