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CRANKSHAFT/TRA NSMISSION 9-1
9
Crankshaft/Transmission
Table of Contents
Exploded View................................... 9-2
Specifications .................................... 9-6
Special Tools and Sealant ................. 9-9
Crankcase Splitting............................ 9-10
Crankcase Splitting ...................... 9-10
Crankcase Assembly ................... 9-10
Crankshaft and Connecting Rods...... 9-13
Crankshaft Removal .................... 9-13
Crankshaft Installation ................. 9-13
Connecting Rod Removal............ 9-13
Connecting Rod Installation......... 9-13
Crankshaft/Connecting Rod
Cleaning.................................... 9-16
Connecting Rod Bend.................. 9-17
Connecting Rod Twist .................. 9-17
Connecting Rod Big E nd Side
Clearance.................................. 9-17
Connecting Rod Big End Bearing
Insert/Crankpin Wear ................ 9-18
Crankshaft Side Clearance.......... 9-19
Crankshaft Runout ....................... 9-20
Crankshaft Main Bearing
Insert/Journal Wear................... 9-20
Starter Motor Clutch .......................... 9-22
Starter Motor Clutch
Removal/Installation.................. 9-22
Starter Motor Clutch Inspection ... 9-22
Starter Motor Clutch Disassembly 9-22
Starter Motor Clutch Assembly .... 9-22
T ransmission ..................................... 9-23
Shift Pedal Removal .................... 9-23
Shift Pedal Installation ................. 9-23
External Shift Mechanism
Removal .................................... 9-24
External Shift Mechanism
Installation ................................. 9-25
External Shift Mechanism
Inspection.................................. 9-25
Transmission Shaft Removal ....... 9-26
Transmission Shaft Installation .... 9-26
Transmission Shaft Disassembly. 9-26
Transmission Shaft Assembly...... 9-27
Shift Drum and Fork Removal...... 9-30
Shift Drum and Fork Installation... 9-30
Shift Drum Disassembly............... 9-30
Shift Drum Assembly ................... 9-30
Shift Fork Bending ....................... 9-31
Shift Fork/Gear Groove Wear ...... 9-31
Shift Fork Guide Pin/Drum
Groove Wear............................. 9-31
Gear Dog and G ear Dog Hole
Damage..................................... 9-31