Honda INTERCEPTOR 2002 Service Manual page 358

CRANKCASE/ TRANSMISSION
SERVICE INFORMATION
GENERAl
• The main journal 9 mm bolts are tightened using the Plastic Region Tightening Method.
• Always use new main journal 9 mm bolts (page 11-13).
• The main journal 9 mm bolt is pre-coated with an oil additive for axial tension stabil ity. Do not remove the oil additive
from the new 9 mm bo lt surface.
• Must be follow the tightening procedure for crankcase bolt tightening (page 11-13).
• The crankcase must be separated to service the following:
- Transmission
- Crankshaft (page 12-4)
- Piston/connecting rod (page 12-11)
• The following components must be removed before separating the crankcase:
- Alternator (page 17-1 0) I flywheel (page 17-11)
- Clutch (page 9-15)
- Gearshift linkage (page 10-5)
- Cylinder head (page 8-1 9)
- Engine (page 7-5)
- Oi l pump (page 4-8)
- Starter motor (page 19-6)
-Water pump (page 6-18)
• Be careful not to damage the crankcase mating surfaces when servicing.
• Prior to assembling the crankcase halves, apply sealant to their mating surfaces, Wipe off excess sealant thoroughly.
SPECIFICATIONS
Unit· mm (in)
ITEM
Transmission Gear I.D.
Gear busing O.D.
Gear-to-bushing
clearance
Gear bushing J.D.
Mainshaft O.D.
1-- C ountershaft O.D.
Bushing-to-shaft
clearance
Shift fork, Fork J.D.
fork shaft
Claw thickness
Shift fork shaft 0.0.
TOEQUE VAlUES
Crankcase bolt, 9 mm (Main journal)
Crankcase bolt, 10mm
7mm
STANDARD SERVICE LIMIT
M5, M6 28.000 - 28.021 ( 1.1024 - 1.1 032) 28.04 (1.104)
C1 26.007 - 26.028 (1.0239 - 1.0247) 26.04 (1.025)
C2 31.000 - 3 1.025 (1.2205 - 1.2215)
31.04 (1.222)
C3,C4 31.000-3 1.025 (1.2205- 1.2215) 31.04 (1.222)
M5, M6 27.959- 27.980 ( 1.1007 - 1.1016) 27.94 (1.100)
C2
30.970 - 30.995 (1.2193 - 1.2203) 30.95 (1.219)
C3,C4
30.950 - 30.975 (1.2185 - 1.2195)
30.93 (1.218)
M5, M6 0.020- 0.062 (0.0008- 0.0024)
-
C2 0.005- 0.055 (0.0002- 0.0022)
-
C3,C4 0.025-0.075 (0.0010 - 0.0030)
-
M5 24.985 - 25.006 (0.9837 - 0.9845) 25.03 (0.985)
C2 28.000-28.021 (1.1024-1.1032) 28.04 (1.104)
at M5 24.959- 24.980 (0.9826- 0.9835) 24.95 (0.982)
at C2
27.967 - 27.980 (1.1011 - 1.1016) 27.96 ( 1.101)
M5 0.005 - 0.047 (0.0002 - 0.0019)
-
C2 0.020- 0.054 (0.0008- 0.0021)
-
14.000-14.021 (0.5512- 0.5520) 14.03 (0.552)
6.43 - 6.50 (0.253- 0.256) 6.40 (0.252)
13.973 - 13.984 (0.5501 - 0.5506) 13.965 (0.5498)
See page page 11-13 Apply oil to t he t hreads and seating sur-
face
39 N·m (4.0 kgf·m, 29 lbf·ft)
18 N·m (1.8 kgf·m, 13 lbf·ft)
11-3
'