CRANKSHAFT INSTALLATION
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RIGHT CRANKCASE |
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CRANKSHAFT |
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Clean both crankcase mating surfaces before assembling and check for wear or damage.
If there is minor roughness or irregularities on the crankcase mating surfaces, dress them with an oil stone.
After cleaning, lubricate the bearings and connecting rod big end with clean engine oil.
Install the crankshaft into the right crankcase.
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Apply molybdenum oil solution to the mainshaft
and countershaft spline area and transmission gear
sliding surface.
Assemble all parts into their original positions.
• Check the gears for freedom of movement or rotation on the shaft.
• Install the washers and snap rings with the chamfered edge facing the thrust load side. Confirm the inner side of snap rings and washer when you detect the chamfered side.
• Do not reuse a worn snap ring which could easily spin in the groove.
• Check that the snap rings are seated in the shaft grooves, and align their end gaps with the grooves of the spline.
MAINSHAFT ('05 -'07):
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MAINSHAFT (After '07): M1 (13T) MAINSHAFT |
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M5 (23T) |
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THRUST WASHERS |
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M4 (19T) |
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M4 BUSHING |
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М2 (16T) |
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М3 (17T) |
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M5 BUSHING SPLINE WASHER |
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SPLINE WASHER |
COUNTERSHAFT ('05 - '07)
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THRUST WASHER |
THRUST WASHER
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SNAP RING SPLINE WASHER |
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NEEDLE BEARING |
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THRUST WASHER |
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COUNTERSHAFT |
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C2 BUSHING THRUST WASHER |
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і |
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THRUST WASHER |
COUNTERSHAFT (After '07):
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SNAP RING |
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C3 BUSHING |
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C1 (29T) |
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THRUST WASHER |
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THRUST WASHER |
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SPLINE WASHER СЗ (21T) |
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THRUST WASHER C4 (19T) |
NEEDLE BEARING THRUST WASHER C5(19T)
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7fc :AII gear teeth |
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MAINSHAFT ASSEMBLY |
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COUNTERSHAFT ASSEMBLY |
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Apply transmission oil to all transmission gear teeth.
Engage the mainshaft and countershaft gears.
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MAINSHAFT/COUNTERSHAFT ASSEMBLY |
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Install the mainshaft and countershaft assembly into the right crankcase.
Make sure the three thrust washers are installed (mainshaft; left only/countershaft; both ends).
Each shift fork has an identification mark, "EYR" is for the right shift fork, "EYL" is the left shift fork and “EYC“ is for the center shift fork.
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“EYL" "EYC" "EYR" |
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SHIFT FORK SHAFTS |
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SHIFT DRUM |
Apply transmission oil to the shift drum guide grooves.
Apply molybdenum oil solution to the following parts:
- Shift fork claws and guide pins
- Shift fork sliding surfaces
- Shift fork shaft
Install the shift forks to the grooves in the sliding gears.
• Face all shift fork marks to the left crankcase.
Install the shift drum by aligning the guide pins on the shift forks with the guide grooves in the shift drum.
Slide the shift fork shafts through the shift forks, and into the crankcase.
