CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER
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• This section covers crankcase separation for service of the crankshaft, transmission and balancer.
• The crankcase must be separated to service the crankshaft and transmission.
• The engine must be out of the frame for this service.
• The following parts must be removed before separating the crankcase.
- Clutch (page 11-7)/stater clutchfpage 11-19)/kickstarter (page 11-15)/gearshift linkage (page 11-24)
- Cylinder head (page 9-24)
- Cylinder (page 10-5)/piston (page 10-6)
- Engine (page 8-5)
- Flywheel (page 12-5)
- Oil pump drive gear/drive pin (page 5-7)
- Starter motor (page 19-6)
- Drive sprocket (page 8-4)
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Unit: mm (in |
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ITEM |
STANDARD |
SERVICE LIMIT |
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Crankshaft |
Side clearance |
0.30-0.75 (0.012-0.030) |
0.75 (0.030) |
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Radial clearance |
0.006 - 0.018 (0.0002 - 0.0007) |
0.05 (0.002) |
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Runout |
R |
- |
0.03 (0.001) |
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L |
- |
0.05 (0.002) |
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Transmission |
Gear I. D. |
M4 |
28.007 - 28.028 (1.1026 - 1.1035) |
28.05(1.104) |
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M5 |
25.020 - 25.041 (0.9850 - 0.9859) |
25.07 (0.987) |
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C1 |
22.007 - 22.028 (0.8664 - 0.8672) |
22.04 (0.868) |
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C2 |
30.020-30.041 (1.1819-1.1827) |
30.07 (1.184) |
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C3 |
25.020 - 25.041 (0.9850 - 0.9859) |
25.07 (0.987) |
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Bushing O. D. |
M4 |
27.959 - 27.980 (1.1007 - 1.1016) |
27.94(1.100) |
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C2 |
29.979-30.000 (1.1803- 1.1811) |
29.95(1.179) |
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Bushing I. D. |
C2 |
27.000 - 27.021 (1.0630 - 1.0638) |
27.04 (1.065) |
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Gear-to-bushing |
M4 |
0.027 - 0.069 (0.0011 - 0.0027) |
0.11 (0.004) |
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clearance |
C2 |
0.020 - 0.062 (0.0008 - 0.0024) |
0.12 (0.005) |
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Mainshaft O. D. |
M5 |
24.959 - 24.980 (0.9826 - 0.9835) |
24.94 (0.982) |
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Countershaft O. D. |
C1 bearing |
18.987 - 19.000 (0.7475 - 0.7480) |
18.94(0.746) |
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C2 bushing |
26.959 - 26.980 (1.0614 - 1.0622) |
26.94(1.061) |
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C3 |
24.959 - 24.980 (0.9826 - 0.9835) |
24.96 (0.983) |
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Gear-to-shaft |
M5 |
0.040 - 0.082 (0.0016 - 0.0032) |
0.13 (0.005) |
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clearance |
C3 |
0.040 - 0.082 (0.0016 - 0.0032) |
0.082 (0.0032) |
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Bushing-to-shaft clearance |
C2 |
0.020 - 0.062 (0.0008 - 0.0024) |
0.12 (0.005) |
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Shift fork, shift |
Fork claw thickness |
4.93-5.00 (0.194-0.197) |
4.8 (0.19) |
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fork shaft |
Shift fork I. D. |
С |
10.989 - 11.011 (0.4326 - 0.4335) |
11.011 (0.4335) |
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R, L |
12.035 - 12.056 (0.4738 - 0.4746) |
12.070 (0.4752) |
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Fork shaft O. D. |
С |
10.969 - 10.980 (0.4319 - 0.4323) |
10.969 (0.4318) |
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R, L |
11.966 - 11.984 (0.4711 - 0.4718) |
11.950 (0.4705) |
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Unit: mm (in)
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