CRANKCASE BEARING REPLACEMENT

CRANKCASE BEARING/OIL SEAL LOCATION

RIGHT COUNTERSHAFT BEARING (5203U)

RIGHT BALANCER SHAFT BEARING (6003)

RIGHT CRANKCASE:

RIGHT CRANKSHAFT BEARING (30 x 76 x 19)

CRANKCASE BEARING REPLACEMENT

SHAFT BEARING (20x32x 14)

LEFT MAINSHAFT BEARING (6203U)

LEFT COUNTERSHAFT BEARING (24 x 56 x 14)

CRANKCASE BEARING REPLACEMENT

TORX SCREWS/SET PLATES

CRANKSHAFT BEARING

CRANKCASE BEARING REPLACEMENT

Remove the torx screws and right crankshaft bear­ing set plates.

Remove the crankshaft oil seals and bearings from both crankcase halves.

Drive in new bearings squarely with the marking side facing toward the inside of the crankcase.

DRIVER

CRANKCASE BEARING REPLACEMENT

07749-0010000

07746-0010500

07749-0010000

07746-0010600

07746-0040700

Clean and apply locking agent to the set plate torx screws.

NOTE:

Use Pro Honda Hondalock 3 or equivalent high strength locking agent.

Install the torx screws with the set plates and tighten to the specified torque.

TORQUE: ’05 — ’07: 10 N m (1.0 kgf m, 7 Ibf ft)

After ’07: 20 N m (2.0 kgf m, 15 lbf-ft)

TOOLS:

Left crankshaft bearing: Driver

Attachment, 62 x 68 mm Right crankshaft bearing: Driver

Attachment, 72 x 75 mm Pilot, 30 mm

Drive new crankshaft bearings into both crankcase halves using the special tools.

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OIL SEAL

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CRANKCASE BEARING REPLACEMENT

0 — 1.0 mm (0 — 0.04 in)

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Apply transmission oil to a new right crankshaft oil seal outer surface.

Install a new right crankshaft oil seal to the crank­case until it is flush with the crankcase surface.

Apply transmission oil to a new left crankshaft oil seal outer surface.

Install a new left crankshaft oil seal to the specified depth below the crankcase surface as shown.

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RIGHT CRANKCASE:

TRANSMISSION/BALANCER BEARINGS

CRANKCASE BEARING REPLACEMENT

SCREWS/SET PLATES

LEFT CRANKCASE

SNAP RING

CRANKCASE BEARING REPLACEMENT

Remove the countershaft and balancer shaft oil seals.

Remove the screws and countershaft bearing set plates.

Remove the snap ring from left crankcase.

Remove the mainshaft bearing, and balancer shaft bearing using the special tools as shown.

BEARING REMOVER

CRANKCASE BEARING REPLACEMENT

TOOLS:

Mainshaft bearing:

Bearing remover set 17 mm Remover handle Remover weight

Balancer shaft bearing: Bearing remover set 20 mm Remover handle Remover weight

ATTACHMENT

DRIVER

CRANKCASE BEARING REPLACEMENT

Drive in new bearings squarely with the marking side facing toward the inside of the crankcase

07749-0010000

07746-0010400

07749-0010000

07746-0010200

07746-0040400

07749-0010000

07746-0010100

07746-0040500

07749-0010000

07746-0010200

07936-3710300 07936-3710100 07741-0010201 or 07936-371020A (U. S.A. only)

07936-3710600 07936-3710100 07741-0010201 or 07936-371020A (U. S.A. only)

Remove the countershaft bearing and shift drum bearing.

Drive new bearings into the left crankcase using the special tools.

TOOLS:

Countershaft bearing:

Driver

Attachment, 52 x 55 mm Mainshaft bearing:

Driver

Attachment, 37 x 40 mm Pilot, 17 mm Balancer shaft bearing:

Driver

Attachment, 32 x 35 mm Pilot, 20 mm Shift drum bearing:

Driver

Attachment, 37 x 40 mm

CRANKCASE BEARING REPLACEMENT

After installing a snap ring, always rotate it in its groove to be sure it is fully seated.

Install the snap ring into the left crankcase securely.

Clean and apply locking agent to the countershaft bearing set plate screws.

SET PLATES/SCREWS

CRANKCASE BEARING REPLACEMENT

Install the screws with the set plates and tighten the screws to the specified torque.

TORQUE: 10 N m (1.0 kgf m, 7 Ibf ft)

Apply grease to new countershaft and balancer shaft oil seal lips.

Install a new balancer shaft oil seal to the crankcase until it is flush with the crankcase surface.

Install a new countershaft oil seal to the specified depth below the crankcase surface as shown.

CRANKCASE BEARING REPLACEMENT

COUNTERSHAFT OIL SEAL:

RIGHT CRANKCASE

Remove the socket bolts and set plates.

Remove the countershaft bearing, mainshaft bear­ing and shift drum bearing.

MAINSHAFT BEARING BOLTS/SET PLATES

CRANKCASE BEARING REPLACEMENT

SHIFT DRUM"

BEARING Ів COUNTERSHAFT BEARING

( BALANCER*SHAFT BEARING

BOLTS/SET PLATES

■ЕНШМОМ

CRANKCASE BEARING REPLACEMENT

Remove the bolts and set plates. Remove the balancer shaft bearing.

Drive in new bearings squarely with the marked side facing toward the inside of the crankcase.

DRIVER

CRANKCASE BEARING REPLACEMENT

07749-0010000

07746-0010200

07746-0040600

07749-0010000

07746-0010400

07746-0040600

07749-0010000

07746-0010200

07746-0040400

07749-0010000

07746-0010100

07746-0040400

Clean and apply locking agent to the set plate bolts. Install the bolts with the set plates and tighten the bolts to the specified torque.

TORQUE:

Gearshift drum bearing set plate bolts:

10 N-m (1.0 kgf-m, 7 Ibf-ft)

Mainshaft bearing set plate bolts:

10 N m (1.0 kgf-m, 7 Ibf-ft)

Balancer shaft bearing set plate bolts:

10 N-m (1.0 kgf-m, 7 Ibf-ft)

TOOLS:

Shift drum bearing:

Driver

Attachment, 37 x 40 mm Pilot, 25 mm Mainshaft bearing:

Driver

Attachment, 52 x 55 mm Pilot, 25 mm Countershaft bearing: Driver

Attachment, 37 x 40 mm Pilot, 17 mm Balancer shaft bearing: Driver

Attachment, 32 x 35 mm Pilot, 17 mm

Drive in new bearings into the right crankcase using the special tools.

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