Crankshaft, Transmission Service Information; Crankshaft, Transmission Troubleshooting - Honda XLR200R Service Manual

10. CRANKSHAFT, TRANSMISSION
SERVICE INFORMATION ................................ 10 - 1
CRANKSHAFT, TRANSMISSION
REMOVAL & ASSEMBLy ................................ 10 - 6
TROUBLESHOOTING ...................................... 10 - 1
MAINSHAFT DISMANTLING & ASSEMBLy .... 10 - 8
COUNTERSHAFT DISMANTLING
CRANKCASE DISMANTLING
&
ASSEMBLY •.. 10 - 2
CRANKCASE BEARING ....•.............................. 10-- 4 &
ASSEMBLY ............................................... 10 - 10
SERVICE INFORMATION
· Crankshaft and transmission maintenance must be done after crankcase dismantling.
• The following parts must be removed before separating the crankcase
-Clutch. Primary Drive Gear (e:>9) -Gearshift Linkage (e:>9-7)
-Flywheel (e:> 14-8) -Cylinder, Piston· (e:>8)
-Cylinder Head (e:>7) -Starter Motor (e:>16-7)
· When removing the crankshaft, make sure nofta scratch or damage the main bearing.
· During assembly, apply engine oil to main bearing.
TROUBLESHOOTING
Engine Noise
Worn out
cranksh~.ft
main bearing
Worn out connecting rod big end bearing
· Bent connecting rod
· Worn out transmission gear
Hard to Shift
Defective clutch adjustment (too much slack)
Bent shift fork
Bent shift fork .shaft
Damaged gearshift spindle
Worn. out shift drum guide
Damaged shift fork guide pin
Transmission Jumps Out of Gear
. Worn gear dogs or·slots
Bent shift fork shaft
Damaged shift drum stopper arm
Damaged shift drum guide groove
Worn out shift fork groove
10-1