CRANKSHAFT INSTALLATION

RIGHT CRANKCASE

CRANKSHAFT

CRANKSHAFT INSTALLATION

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.

TRANSMISSION ASSEMBLY

CRANKSHAFT INSTALLATION

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):

CRANKSHAFT INSTALLATION

MAINSHAFT (After ’07): M1 (13T) MAINSHAFT

M5 (23T)

THRUST WASHERS

M4 (19T)

M4 BUSHING

М2 (16T)

М3 (17T)

CRANKSHAFT INSTALLATION

M5 BUSHING SPLINE WASHER

CRANKSHAFT INSTALLATION

SPLINE WASHER

CRANKSHAFT INSTALLATION

COUNTERSHAFT (’05 — ’07)

THRUST

WASHER

THRUST WASHER

SNAP RING

SPLINE WASHER

NEEDLE BEARING

THRUST

WASHER

COUNTERSHAFT

C2 BUSHING

THRUST

WASHER

і

THRUST WASHER

COUNTERSHAFT (After ’07):

SNAP RING

C3 BUSHING

C1 (29T)

THRUST WASHER

THRUST

WASHER

CRANKSHAFT INSTALLATION

SPLINE WASHER СЗ (21T)

THRUST WASHER C4 (19T)

NEEDLE BEARING THRUST WASHER C5(19T)

INSTALLATION

7fc :AII gear teeth

MAINSHAFT ASSEMBLY

COUNTERSHAFT ASSEMBLY

CRANKSHAFT INSTALLATION

Apply transmission oil to all transmission gear teeth.

Engage the mainshaft and countershaft gears.

MAINSHAFT/COUNTERSHAFT ASSEMBLY

CRANKSHAFT INSTALLATION

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.

CRANKSHAFT INSTALLATION

“EYL" "EYC" "EYR"

CRANKSHAFT INSTALLATION

SHIFT FORK SHAFTS

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.

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