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11.
CRANKSHAFT/TRANSMISSION
SERVICE
INFORMATION
11-1
TROUBLESHOOTING
11-2
CRANKCASE
SEPARATION
11-3
TRANSMISSION
11-4
CRANKSHAFT
11-8
CRANKCASE
BEARING
REPLACEMENT
11-10
CRANKCASE ASSEMBLY
11-13
SERVICE
INFORMATION
GENERAL
•
For crankshaft
and
transmission
repair,
the crankcase
must be
separated.
•
The
following parts
must be removed
before separating the crankcase.
—
Alternator/starrer clutch
(Section
10)
—
Cylinder/piston (Section
8)
—
Clutch/gearshift linkage (Section
9)
—
Engine
(Section 8)
—
Cylinder
head
(Section
7)
—
Oil
pump
(Section
4)
SPECIFICATIONS
Unit
mm
(in)
ITEM
STANDARD
SERVICE
LIMIT
Crankshaft
Connecting rod
big
end
side clearance
Radial
clearance
1
0.10 - 0.40(0.004 - 0.016)
0.004 - 0.012
(0.0002
-
0.0005)
—
0.60
(0.024)
0.05
(0.002)
0
03
(0
001)
At bearing holder
0.05
(0.002)
Transmission
j
Gear
1.0.
M5
20.020
-
20.041 (0.7882
-
0.7890)
20.08(0.791)
Cl
20.020
-
20.041 (0.7882
-
0.7890)
20
08
(0.791)
C4
20.020 -
20.041 (0.7882
-
0.7890)
20.08
(0.791)
Gear bushing
O.O.
Cl
19.979
-
20.000 (0.7866
-
0.7874)
19.93
(0
785)
Gear bushing
I.D.
Cl
16.516 - 16.534 (0.6502
-
0.6509)
16.58(0.653)
Gear-to-bushing clearance
Cl
0.020 - 0.062 (0.0008 - 0.0024)
0.10
(0.004)
Malnshaft O.D.
ca
19.959
-
19.980 (0.7858
-
0.7866)
19.91 (0.784)
Countershaft O.D.
Cl
16.466
-
16.484 (0.6475
-
0.6490)
16.41 (0.646)
Gear-to-shaft
chearance
C4
19.959
-
19.980 (0.7858
-
0.7886)
19.91 (0.784)
EH
0.040
-
0.082 (0.0016
- 0.0032)
0.10(0.004)
Bushlng-to-shaft clearance
C4
0.040 - 0.082 (0.0016 - 0.0032)
0.10(0.004)
Cl
0.032
-
0.068 (0.0013
- 0.0027)
0.10(0.004)
Shift fork.
Fork
I.D.
12.000
-
12.018 (0.4724
- 0.4731)
12.05
(0.474)
shaft
Claw
thickness
4.93-5.00 (0.194-0.197)
4.80(0.189)
Fork
shaft
O.D.
11.976- 11.994(0.4724-0.4731)
11.93 (0.470)
TORQUE
VALUES
Crankshaft
mounting
bolt
Crankshaft
mounting
nut
Oil
passage
plate
mounting screw
23
N-m
(2.3
kgf-m, 17
lbf-ft)
12
N-m
(1.2
kgf-m.
9
lbf-ft)
10
N-m
(1.0
kgf-m,
7
lbf-ft)
Apply
a
locking agent
to
the threads
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