CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER

COMPONENT LOCATION

CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER

SERVICE INFORMATION

GENERAL

• 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)

SPECIFICATIONS (’05 — ’07)

Unit: mm (in

ITEM

STANDARD

SERVICE LIMIT

Crankshaft

Side clearance

0.30-0.75 (0.012-0.030)

0.75 (0.030)

Radial clearance

0.006 — 0.018 (0.0002 — 0.0007)

0.05 (0.002)

Runout

R

0.03 (0.001)

L

0.05 (0.002)

Transmission

Gear I. D.

M4

28.007 — 28.028 (1.1026 — 1.1035)

28.05(1.104)

M5

25.020 — 25.041 (0.9850 — 0.9859)

25.07 (0.987)

C1

22.007 — 22.028 (0.8664 — 0.8672)

22.04 (0.868)

C2

30.020-30.041 (1.1819-1.1827)

30.07 (1.184)

C3

25.020 — 25.041 (0.9850 — 0.9859)

25.07 (0.987)

Bushing O. D.

M4

27.959 — 27.980 (1.1007 — 1.1016)

27.94(1.100)

C2

29.979-30.000 (1.1803- 1.1811)

29.95(1.179)

Bushing I. D.

C2

27.000 — 27.021 (1.0630 — 1.0638)

27.04 (1.065)

Gear-to-bushing

M4

0.027 — 0.069 (0.0011 — 0.0027)

0.11 (0.004)

clearance

C2

0.020 — 0.062 (0.0008 — 0.0024)

0.12 (0.005)

Mainshaft O. D.

M5

24.959 — 24.980 (0.9826 — 0.9835)

24.94 (0.982)

Countershaft O. D.

C1 bearing

18.987 — 19.000 (0.7475 — 0.7480)

18.94(0.746)

C2 bushing

26.959 — 26.980 (1.0614 — 1.0622)

26.94(1.061)

C3

24.959 — 24.980 (0.9826 — 0.9835)

24.96 (0.983)

Gear-to-shaft

M5

0.040 — 0.082 (0.0016 — 0.0032)

0.13 (0.005)

clearance

C3

0.040 — 0.082 (0.0016 — 0.0032)

0.082 (0.0032)

Bushing-to-shaft

clearance

C2

0.020 — 0.062 (0.0008 — 0.0024)

0.12 (0.005)

Shift fork, shift

Fork claw thickness

4.93-5.00 (0.194-0.197)

4.8 (0.19)

fork shaft

Shift fork I. D.

С

10.989 — 11.011 (0.4326 — 0.4335)

11.011 (0.4335)

R, L

12.035 — 12.056 (0.4738 — 0.4746)

12.070 (0.4752)

Fork shaft O. D.

С

10.969 — 10.980 (0.4319 — 0.4323)

10.969 (0.4318)

R, L

11.966 — 11.984 (0.4711 — 0.4718)

11.950 (0.4705)

SPECIFICATIONS (After ’07)

Unit: mm (in)

ITEM

STANDARD

SERVICE LIMIT

і Crankshaft

Side clearance

0.30-0.75 (0.012-0.030)

0.75 (0.030)

Radial clearance

0.006 — 0.018 (0.0002 — 0.0007)

0.05 (0.002)

Runout

R

0.03(0.001)

L

0.05 (0.002)

Transmission

Gear I. D.

M4

28.007 — 28.028 (1.1026 — 1.1035)

28.05 (1.104)

M5

28.020 — 28.033 (1.1031 — 1.1037)

28.07 (1.105)

C1

22.007 — 22.028 (0.8664 — 0.8672)

22.04 (0.868)

C2

30.020 — 30.041 (1.1819 — 1.1827)

30.07 (1.184)

C3

28.020 — 28.041 (1.1031 — 1.1040)

28.07 (1.105)

Bushing O. D.

M4

27.959 — 27.980 (1.1007 — 1.1016)

27.94 (1.100)

M5

27.959 — 27.980 (1.1007 — 1.1016)

27.94 (1.100)

C2

29.979 — 30.000 (1.1803 — 1.1811)

29.95 (1.179)

C3

27.979-28.000(1.1015- 1.1024)

27.95 (1.100)

Bushing I. D.

M5

25.000 — 25.021 (0.9843 — 0.9851)

25.04 (0.9858)

C2

27.000 — 27.021 (1.0630 — 1.0638)

27.04 (1.065)

C3

25.000-25.021 (0.9843-0.9851)

25.04 (0.9858)

Gear-to-bushing

M4

0.027 — 0.069 (0.0011 — 0.0027)

0.11 (0.004)

clearance

M5

0.040 — 0.074 (0.0016 — 0.0029)

0.12 (0.005)

C3

0.020 — 0.062 (0.0008 — 0.0024)

0.12 (0.005)

C2

0.020 — 0.062 (0.0008 — 0.0024)

0.12(0.005)

Mainshaft O. D.

M5

24.959 — 24.980 (0.9826 — 0.9835)

24.94 (0.982)

Countershaft O. D.

C1 bearing

18.987 — 19.000 (0.7475 — 0.7480)

18.94 (0.746)

C2 bushing

26.959 — 26.980 (1.0614 — 1.0622)

26.94 (1.061)

C3 bushing

24.959 — 24.980 (0.9826 — 0.9835)

24.96 (0.983)

Bushing-to-shaft

clearance

M5, C2, C3

0.020 — 0.062 (0.0008 — 0.0024)

0.12 (0.005)

Shift fork, shift

Fork claw thickness

4.93-5.00 (0.194-0.197)

4.8 (0.19)

fork shaft

Shift fork I. D.

С

10.989 — 11.011 (0.4326 — 0.4335)

11.011 (0.4335)

R, L

12.035 — 12.056 (0.4738 — 0.4746)

12.070 (0.4752)

Fork shaft O. D.

С

10.969 — 10.980 (0.4319 — 0.4323)

10.969 (0.4318)

R, L

11.966 — 11.984 (0.4711 — 0.4718)

11.950 (0.4705)

Добавить комментарий

Ваш e-mail не будет опубликован. Обязательные поля помечены *

Confirm that you are not a bot - select a man with raised hand: