Crankcase/Transmission/Kickstarter Contents - Honda CB HORNET 160R 2015 Shop Manual

11. CRANKCASE/TRANSMISSION/KICKSTARTER
COMPONENT LOCATION
SERVICE INFORMATION
TROUBLESHOOTING
CRANKCASE SEPARATION
SERVICE INFORMATION
GENERAL
• The following components must be removed before separating the crankcase:
– Engine (page 6-2)
– Cylinder head cover (page 7-4)
– Cylinder head (page 7-10)
– Cylinder/piston (page 8-2)
– Clutch (page 9-6)
– Oil pump (page 4-2)
– Gearshift linkage (page 9-12)
– Flywheel (page 10-4)
– Neutral switch (page 17-12)
– Primary drive gear (page 9-14)
– Remove vehicle speed sensor (page 17-7)
• Be careful not to damage the crankcase mating surfaces when servicing.
• Clean the oil passages before assembling the crankcase halves.
SPECIFICATIONS
Runout
Crankshaft Connecting rod big end radial clearance
Connecting rod big end side clearance
Gear I.D.
Bushing O.D.
Gear-to-bushing
clearance
Transmission
Bushing I.D.
Mainshaft /
countershaft
O.D.
Bushing-to-shaft
clearance
Shift fork shaft O.D.
Shift fork,
Shift fork I.D.
shift fork shaft
Shift fork claw thickness
Kickstarter drive gear I.D
Kickstarter spindle O.D. at Kickstarter drive gear
11-0
11-1
11-2
11-4
ITEM
M4
M5
C1
C2
C3
C1
C2
C1
C2
C1
C2
C1
C2
M4
M5
C1
C2
TRANSMISSION
CRANKSHAFT
CRANKCASE ASSEMBLY
KICKSTARTER
STANDARD
–
0 – 0.008 (0 – 0.0003)
0.10 – 0.35 (0.003 – 0.014)
20.000 – 20.018 (0.7874 – 0.7882)
17.000 – 17.018 (0.6692 – 0.6699)
20.500 – 20.521 (0.8071 – 0.8079)
23.020 – 23.041 (0.9063 – 0.9071)
20.020 – 20.038 (0.7881 – 0.7888)
20.459 – 20.480 (0.8055 – 0.8063)
22.984 – 23.005 (0.9049 – 0.9057)
0.020 – 0.062 (0.0008 – 0.0024)
0.015 – 0.057 (0.0006 –0.0022)
17.000 – 17.018 (0.6693 – 0.6699)
20.020 – 20.041 (0.7882 – 0.7890)
16.966 – 16.984 (0.6680 – 0.6687)
19.978 – 19.989 (0.7865 – 0.7870)
19.968 – 19.980 (0.7861 – 0.7866)
16.968 – 16.980 (0.6679 – 0.6686)
0.016 – 0.052 (0.0006 – 0.0020)
0.031 – 0.063 (0.0012 – 0.0025)
9.986 – 9.995 (0.3931 – 0.3935)
10.000 – 10.018 (0.3937 – 0.3944)
4.930 - 5.000 (0.194 - 0.197)
20.00- 20.21 (0.7873 - 0.7956)
19.959 - 19.980 (0.7875 - 0.7866)
11-6
11-8
11-17
11-21
Unit: mm (in)
11
SERVICE LIMIT
0.03 (0.0007)
0.05 (0.002)
0.80 (0.032)
20.05 (0.789)
17.05 (0.671)
20.55 (0.809)
23.07 (0.908)
20.07 (0.790)
20.41 (0.804)
22.95 (0.904)
0.10 (0.004)
0.10 (0.004)
17.04 (0.671)
20.07 (0.790)
16.93 (0.667)
19.94 (0.785)
19.94 (0.785)
16.93 (0.666)
0.10 (0.004)
0.20 (0.008)
9.93 (0.391)
10.05 (0.396)
4.500 (0.177)
16.06 (0.632)
15.94 (0.628)
11-1