Transmission / Crankshaft/ Kick Starter Service Information; Transmission / Crankshaft/ Kick Starter Service Data; Transmission / Crankshaft/ Kick Starter Troubleshooting; Hard To Shift - Sachs Bikes madass Repair Instructions

TRANSMISSION / CRANKSHAF T/ KICK STARTER
SERVICE INFORMATION
GENERAL
The crankcase must be separated to Service the components covered in the section.
The following parts/systems must be removed before the crankcase can be separated:
- Engine removal
- Cylinder head
- Cylinder/piston
- Clutch/gearshift linkage
- Alternator/cam chain tensioner
- Oil pump
SERVICE DATA
ITEM
Crankshaft Connecting rod small end I.D.
Connecting rod big end
clearance
Runout
Transmission Mainshaft O.D.
Countershaft O.D.
Gearshift fork
Gearshift drum O.D.
TORQUE VALUE
Shift drum bolt 12 Nm
TOOLS
Special
Universal bearing puller
Common
Inner driver
Attachment, 20 mm
Driver
Attachment, 37 x 40 mm
Pilot, 17 mm
148
Axial
Radial
M2
C1
I.D.
Claw thickness
TROUBLESHOOTING

Hard to shift

-
-
-
-
-
Transmission Jumps out of gear
-
-
-
Engine noise
-
-
-
-
Transmission noise
-
-
STANDARD
13.016-13.043
0.100-0.350
0-0.012
—
16.983-16.994
19.959-19.980
34.000 34.025
4.86-4.94
33.950-33.975
Incorrect clutch adjustment
Bent gearshift fork
Worn gear dogs
Damaged gearshift drum groove
Damaged guide pin
Worn gear dogs
Bent gearshift fork
Damaged gearshift drum stopper
Worn main Journal bearing
Worn crankpin bearing
Worn piston pin
Worn piston pin bore
Worn gears
Damaged or worn mainshaft and/or countershaft
Unit: mm
SERVICE LIMIT
13.06
0.60
0.05
0.10
16.94
19.94
34.14
4.60
33.93