Crankcase/Transmission - Honda C8R600F4 Service Manual

11.
CRANKCASE/TRANSMISSION
SERVICE INFORMATION
TROUBLESHOOTING
CRANKCASE SEPARATION
SERVICE INFORMATION
GENERAL
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•The crankcase must be separated to service the following:
-transmission
-crankshaft (section 12)
-piston/connecting rod (section 12)
SHIFT FORK/SHIFT DRUM
TRANSMISSION
CRANKCASE ASSEMBLY
•The following components must be removed before separating the crankcase:
-engine (section 7) ·
- oil pan, oil pump and oil cooler (section 4)
-water pump (section 6)
-cylinder head (section 8)
-clutch/gearshift linkage (section 9)
-flywheel (section 10)
- starter motor (section 18)
• Be careful not to damage the crankcase mating surfaces when servicing.
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• Prior to assembling the crankcase halves, apply sealant to their mating surfaces. Wipe off excess sealant thoroughly.
m
SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Shift fork l.D. 12.000-12.021 (0.4724-0.4733)
12.03 (0.474)
Claw thickness 5.93-6.00 (0.233-0.236) 5.9 (0.23)
Shift fork shaft
0.D. 11.957-11.968 (0.4707-0.4712) 11.95 (0.470)
Transmission
Gear l.D. M5,M6 28.000-28.021 (1.1024-1.1032) 28.04 (1.104)
C2,C3,C4 31.000-31.025 (12205-1.::i?1!'>) 31.04 ( 1.222)
Gear bushing O.D.
I
M5,M6 27.959-27.980 (1.1007-1.1016) 27.94 (1.100)
C2 30.955-30.980 (1.2187-1.2197) 30.94 (1.218)
C3,C4 30.950-30.975 (1.2185-1.2195) 30.93 (1.218)
Gear-to-bushing
M5, M6
0.020-0.062 (0.0008-0.0024) 0.10 (0.004)
clearance C2
0.020- 0.070 (0.0008-0.0028)
0.10 (0.004)
C3,C4 0.025-0.075 (0.0010-0.0030) 0.11 (0.004)
Gear bushing l.D.
I
M5 24.985- 25.006 (0.9837 - 0.9845) 25.016 (0.9849)
C2 27.985-28.006 (1.1018-1.1026) 28.021 ( 1.1032)
Mainshaft 0.D. atM5 24.967 - 24.980 (0.9830- 0.9835) 24.96 (0.983)
Countershaft 0.D.
at C2
27.967-27.980 (1.1011-1.1016)
27.96 (1.101)
Bul5i 1i111,,i-Lu-:>haft
Mu
0.005 0.039 (0.0002 0.0015) 0.06 (0.002)
clearance C2 0.005-0.039 (0.0002-0.0015) 0.06 (0.002)
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