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10. FINAL REDUCTION AGILITY 50

10




10




10-0
10. FINAL REDUCTION AGILITY 50

SERVICE INFORMATION.......................10-1 FINAL REDUCTION INSPECTION...... 10-2
TROUBLESHOOTING..............................10-1 BEARING REPLACEMENT.................. 10-3
FINAL REDUCTION DISASSEMBLY....10-2 FINAL REDUCTION ASSEMBLY........ 10-4



SERVICE INFORMATION
SPECIFICATIONS
Specified Oil: GEAR OIL SAE 90#
Oil Capacity: At disassembly : 0.11 liter
At change : 0.10 liter


SPECIAL TOOLS
Bearing puller, 10,12,15,18mm




TROUBLESHOOTING
Engine starts but motorcycle won`t move
Damaged transmission
Seized or burnt transmission
Faulty drive belt
Faulty clutch

Abnormal noise
Worn, seized or chipped gears
Worn bearing

Oil leaks
Oil level too high
Worn or damaged oil seal




10-1
10. FINAL REDUCTION AGILITY 50
Bolt
FINAL REDUCTION DISASSEMBLY
Remove the rear brake cable. ( 13-3)
Remove the rear wheel. ( 13-2)
Remove the left crankcase cover. ( 9-2)
Remove the clutch/driven pulley. ( 9-10)
Drain the transmission gear oil into a clean
container.
Remove the transmission case cover
attaching bolts.
Remove the transmission case cover.
Remove the gasket and dowel pins.


Drive Shaft
Remove the final gear and countershaft.




Final Gear Countershaft

FINAL REDUCTION INSPECTION
Inspect the countershaft and gear for wear or
damage.




Countershaft

Inspect the final gear and final shaft for wear,
damage or seizure.




Final Shaft
10-2
10. FINAL REDUCTION AGILITY 50
Drive Shaft Bearing
Check the left crankcase bearings for
excessive play and inspect the oil seal for
wear or damage.




Final Shaft Bearing Countershaft Bearing

Inspect the drive shaft and gear for wear or
damage.
Check the transmission case cover bearings
for excessive play and inspect the final shaft
bearing oil seal for wear or damage.

Do not remove the transmission case
cover except for necessary part replace-
ment. When replacing the drive shaft,
also replace the bearing and oil seal.


Countershaft Bearing Drive Shaft Bearing Oil Seal
Final Shaft Bearing
BEARING REPLACEMENT
(TRANSMISSION CASE COVER)
Remove the transmission case cover bearings
using a bearing puller.
Remove the final shaft oil seal.

Special
Bearing Puller



Bearing Puller

Drive new bearings into the transmission case
cover.




Outer Driver, 32x35mm
10-3
10. FINAL REDUCTION AGILITY 50

BEARING REPLACEMENT (LEFT
CRANKCASE)
Remove the drive shaft.
Remove the drive shaft oil seal.
Remove the left crankcase bearings using a
bearing puller.
Special
Bearing Puller



Bearing Puller, 12mm

Drive new bearings into the left crankcase.
Install a new drive shaft oil seal.




Pilot

FINAL REDUCTION ASSEMBLY
Install the drive shaft into the left crankcase.




Drive Shaft

Install the final gear and final shaft into the
left crankcase.




10-4
10. FINAL REDUCTION AGILITY 50
Resin Washer Countershaft
Install the countershaft and gear into the left
crankcase.
Install the resin washer onto the countershaft.
Install the dowel pins and a new gasket.




Gasket Dowel Pins

Install the transmission case cover.




Transmission Case Cover

Install and tighten the transmission case cover
bolts.
Install the clutch/driven pulley. ( 9-13)




After installation, fill the transmission case
with the specified oil. ( 3-7)

Place the motorcycle on its main stand
on level ground.
Check the oil sealing washer for wear Bolt
or damage.
Specified Gear Oil: SAE90#
Oil Capacity:
At disassembly : 0.11 liter
At change : 0.10 liter
Install and tighten the oil check bolt.
Torque: 0.81.2kgf-m
Start the engine and check for oil leaks.
Check the oil level from the oil check bolt
hole and add the specified oil to the proper
level if the oil level is low.
Drain Bolt Oil Check Bolt Hole/Oil Filler
10-5