Crankcase/Crankshaft/Transmission/Balancer Component Service Information - Honda CRF450X 2005 Service Manual

r -.
l
CRANKCASE/CRANKSHAFT/ TRANSMISSION / BALANCER
SERVICE INFORMATION
GENERAL
• This section covers crankcase separation for service of the crankshaft, transmission a nd balancer.
• The crankcase must be separated to service the crankshaft and transmission.
• The engine must be out of the frame for this service.
• The following parts must be removed before separating the crankcase.
- Clutch (page 11 -7)/stater clutch(page 11-1 9J/kickstarter (page 11-151/gearshift li nkage (page 11-24)
- Cylinder head (page 9-24)
- Cylinder (page 10-5)/piston (page 10-6)
- Engine (page 8-5)
- Flywheel (page 12-5)
- Oil pump drive gear/drive pin (page 5-7)
- Starter motor (page 19-6)
- Drive sprocket (page 8-4)
SPECIFICATIONS ('05 - '07)
ITEM
STANDARD
Crankshaft
Side clearance
0.30 0.75 (0.012 0.030)
Radial clearance
0.006 0.018 (0.0002 - 0.0007)
Runout
R
-
L
-
Transmission Gear LO.
M4
28.007 - 28.028
(1.1026 1.1035)
M5
25.020 - 25.041 (0.9850 - 0.9859)
C1
22.007
22.028 (0.8664 0.8672)
C2 30.020 30.041 (1.1819 1.1827)
C3 25.020 - 25.041 (0.9850 0.9859)
Bushing 0.0.
M4
27.959
27.980 (1. 1007 1.1016)
C2 29.979 30.000 (1.1803 1.1811)
Bushing LD.
C2
27.000 27.021 (1.0630
1.0638)
Gear-to-bushing
M4
0.027 0.069 (0.0011
0.0027)
clearance
C2
0.020 0.062 (0.0008 0.0024)
Mainshaft 0.0.
M5 24.959 24.980 (0.9826 0.9835)
Countershaft 0.0. Cl bearing
18.987 19.000 (0.7475
0.7480)
C2 bushing
26.959 26.980 (1.06 14 1.0622)
C3 24.959 24.980 (0.9826 0.9835)
Gear-to-shaft
M5 0.040 0.082 (0.0016 0.0032)
clearance C3 0.040 0.082 (0.0016 - 0.0032)
Bushing-to·shaft
C2 0.020 - 0.062 (0.0008 - 0.0024)
clearance
Shift fork, shift Fork ctaw thickness 4.93
5.00 (0.194 - 0.197)
fork shaft
Shift fork 1.0.
C 10.989 11.011 (0.4326 0.4335)
R, L
12.035 - 12.056 (0.4738 0.4746)
Fork shaft 0.0.
C
10.969 - 10.980 (0.43 19 0.4323)
R, L 11.966 11.984 (0.471'
0.4718)
Unit· mm (in)
SERVICE LIMIT
0.75 (0.030)
0.05 (0.002)
0.03 (0.001)
0.05 (0.002)
28.05 (1. 104)
25.07 (0.987)
22.04 (0.868)
30.07 (1. 184)
25.07 (0.987)
27.94(1.100)
29.95 (1.179)
27.04 (1.065)
0.11 (0.004)
0.12 (0.005)
24.94 (0.982)
18.94 (0.746)
26.94 (1.061)
24.96 (0.983)
0.13 (0.005)
0.082 (0.0032)
0.12 (0.005)
4.8 (0. 19)
nOll (0.4335)
12.070 (0.4752)
10.969 (0.4318)
11.950 (0.4705)
13-3