Service Information - Honda Transalp XL700V Manual

SERVICE INFORMATION

GENERAL
• The crankcase must be separated to service the following:
– Oil pump (page 4-5)
– Crankshaft/connecting rod (page 12-8)
– Transmission (page 12-19)
• The following parts must be removed before separating the crankcase:
– Oil filter (page 3-13)
– Water pump (page 6-14)
– Cylinder head (page 8-13)
– Cylinder (page 9-4)
– Piston (page 9-5)
– Clutch (page 10-6)
– Gearshift linkage (page 10-14)
– Primary drive gear (page 10-12)
– Flywheel (page 11-6)
– Starter motor (page 19-6)
– Neutral switch (page 20-24)
– EOP switch (page 20-19)
• Be careful not to damage the crankcase mating surfaces when servicing.
• Mark and store the connecting rods, bearing caps and bearing inserts to be sure of their correct locations for reassem-
bly.
• The crank pin and main journal bearing inserts are select fit and are identified by color codes. Select replacement bear-
ings from the code tables. After selecting new bearings, recheck the oil clearance. Incorrect oil clearance can cause
major engine damage.
• Prior to assembling the crankcase halves, apply sealant to their mating surfaces. Wipe off excess sealant thoroughly.
SPECIFICATIONS
Crankshaft Connecting rod big end side
clearance
Crankpin bearing oil clearance
Main journal oil clearance
Crankshaft runout
Main journal O.D.
Main journal I.D.
Shift fork, fork I.D.
shaft
Claw thickness
Fork shaft O.D.
Shift drum O.D.
Shift drum journal I.D.
Shift drum-to-shift drum journal clearance
Transmission Gear I.D.
Gear busing O.D.
Gear-to-bushing
clearance
Gear bushing I.D.
Mainshaft O.D.
Countershaft O.D.
Bushing-to-shaft
clearance
ITEM
M3, M5
C1, C2, C4
M3, M5
C1, C2, C4
M3, M5
C1, C2, C4
M3
C2
at M3
at C2
M3
C2
CRANKCASE/CRANKSHAFT/TRANSMISSION
STANDARD
0.15 – 0.30 (0.006 – 0.012)
0.028 – 0.052 (0.0011 – 0.0020)
0.020 – 0.038 (0.0008 – 0.0015)
–
52.976 – 52.994 (2.0857 – 2.0864)
58.010 – 58.022 (2.2839 – 2.2843)
13.000 – 13.021 (0.5118 – 0.5126)
5.93 – 6.00 (0.233 – 0.236)
12.966 – 12.984 (0.5105 – 0.5112)
11.966 – 11.984 (0.4711 – 0.4718)
12.000 – 12.018 (0.4724 – 0.4731)
0.016 – 0.052 (0.0006 – 0.0020)
28.000 – 28.021 (1.1024 – 1.1032)
31.000 – 31.025 (1.2205 – 1.2215)
27.959 – 27.980 (1.1007 – 1.1016)
30.950 – 30.975 (1.2185 – 1.2195)
0.020 – 0.062 (0.0008 – 0.0024)
0.025 – 0.075 (0.0010 – 0.0030)
25.000 – 25.021 (0.9843 – 0.9851)
27.995 – 28.016 (1.1022 – 1.1030)
24.972 – 24.993 (0.9831 – 0.9840)
27.967 – 27.980 (1.1011 – 1.1016)
0.007 – 0.049 (0.0003 – 0.0019)
0.015 – 0.049 (0.0006 – 0.0019)
Unit: mm (in)
SERVICE LIMIT
0.40 (0.015)
0.07 (0.003)
0.07 (0.003)
0.03 (0.001)
52.976 (2.0857)
58.070 (2.2862)
13.03 (0.513)
5.6 (0.22)
12.90 (0.508)
11.94 (0.470)
12.05 (0.474)
0.09 (0.003)
28.04 (1.104)
31.05 (1.222)
27.940 (1.1000)
30.93 (1.218)
0.08 (0.003)
0.11 (0.004)
25.04 (0.986)
28.03 (1.103)
24.95 (0.982)
27.95 (1.100)
0.09 (0.003)
0.08 (0.003)
12-3