Crankshaft/Transmission - Honda XL200 2001 Shop Manual

XL2 0 0
SERVICE INFORMATION
TROUBLESHOOTING
CRANKCASE SEPARATION
TRANSMISSION
SERVICE INFORMATION
GENERAL
• The crankcase must be separated to repair the crankshaft, transmission.
• Remove the following parts before separating the crankcase.
– Alternator (Section 9)
– Clutch/Gearshift Linkage (Section 8)
– Cylinder head (Section 6)
– Cylinder/piston (Section 7)
– Starter motor (Section 17 or 32)
SPECIFICATIONS
ITEM
Crankshaft runout
Connecting rod big end side clearance
Connecting rod big end radial clearance
Shift fork I.D.
Shift fork claw thickness
Shift fork shaft O.D.
Gear I.D.
Bushing I.D.
Bushing O.D.
Mainshaft O.D.
Countershaft O.D.
Gear-to-bushing
clearance
Bushing-to-shaft
clearance
10-1
10-2
10-3
10-4
M 3, M 5, C 4
C 1
C 2
C 1
C 2
C 1
C 2
At M3 gear
At C 1 bushing
At C 2 bushing
At C 4 gear
M 3
C 4
C 1
C 2
10.
CRANKCASE BEARING REPLACEMENT
CRANKSHAFT
CRANKCASE ASSEMBLY
STANDARD
–
0.05 – 0.30 (0.002 – 0.012)
0 – 0.008 (0 – 0.0003)
12.000 – 12.018 (0.4724 – 0.4731)
4.93 – 5.00 (0.194 – 0.197)
11.976 – 11.994 (0.4715 – 0.4722)
20.020 – 20.041 (0.7882 – 0.7890)
19.520 – 19.541 (0.7685 – 0.7693)
23.020 – 23.041 (0.9063 – 0.9071)
16.500 – 16.518 (0.6496 – 0.6503)
20.000 – 20.021 (0.7874 – 0.7882)
19.479 – 19.500 (0.7667 – 0.7677)
22.979 – 23.000 (0.9047 – 0.9055)
19.959 – 19.980 (0.7858 – 0.7866)
16.466 – 16.484 (0.6482-0.6489)
19.974 – 19.987 (0.7863 - 0.7868)
19.959 – 19.980 (0.7857 - 0.7866)
0.040 – 0.082 (0.001 - 0.003)
0.040 – 0.082 (0.001 - 0.003)
0.016 – 0.052 (0.0006 - 0.002)
0.013 – 0.047 (0.0005 - 0.0018)
CRANKSHAFT/
TRANSMISSION
10-8
10-9
10-11
UNIT: mm (in)
SERVICE LIMIT
0.10 (0.004)
0.5 (0.02) 10
0.05 (0.002)
12.05 (0.474)
4.50 (0.1777)
11.96 (0.471)
20.07 (0.790)
19.57 (0.770)
23.07 (0.908)
16.55 (0.652)
20.05 (0.789)
19.43 (0.765)
22.93 (0.903)
19.91 (0.784)
16.41 (0.646)
19.92 (0.784)
19.90 (0.783)
0.10 (0.004)
0.10 (0.004)
0.08 (0.003)
0.08 (0.003)
1 0 -1