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CRANKSHAFT/TRANSMISSION 9-1
9
Crankshaft/Transmission
Table of Contents
Exploded View........................................................................................................................ 9-2
Specifications ......................................................................................................................... 9-6
Special Tools and Sealants .................................................................................................... 9-9
Crankcase Splitting................................................................................................................. 9-10
Crankcase Splitting........................................................................................................... 9-10
Crankcase Assembly ........................................................................................................ 9-11
Crankshaft and Connecting Rods........................................................................................... 9-16
Crankshaft Removal ......................................................................................................... 9-16
Crankshaft Installation ...................................................................................................... 9-16
Connecting Rod Removal................................................................................................. 9-16
Connecting Rod Installation.............................................................................................. 9-17
Crankshaft/Connecting Rod Cleaning............................................................................... 9-20
Connecting Rod Bend....................................................................................................... 9-20
Connecting Rod Twist....................................................................................................... 9-21
Connecting Rod Big End Side Clearance ......................................................................... 9-21
Connecting Rod Big End Bearing Insert/Crankpin Wear .................................................. 9-21
Crankshaft Side Clearance ............................................................................................... 9-23
Crankshaft Runout ............................................................................................................ 9-23
Crankshaft Main Bearing Insert/Journal Wear .................................................................. 9-24
Pistons.................................................................................................................................... 9-26
Piston Removal................................................................................................................. 9-26
Piston Installation..............................................................................................................9-27
Cylinder Wear (Upper Crankcase).................................................................................... 9-28
Piston Wear ......................................................................................................................9-28
Piston Ring, Piston Ring Groove Wear............................................................................. 9-28
Piston Ring Groove Width................................................................................................. 9-29
Piston Ring Thickness ...................................................................................................... 9-29
Piston Ring End Gap ........................................................................................................ 9-29
Transmission .......................................................................................................................... 9-30
Shift Pedal Removal ......................................................................................................... 9-30
Shift Pedal Installation ...................................................................................................... 9-30
External Shift Mechanism Removal .................................................................................. 9-30
External Shift Mechanism Installation ............................................................................... 9-31
External Shift Mechanism Inspection................................................................................ 9-31
Transmission Shaft Removal ............................................................................................ 9-32
Transmission Shaft Installation ......................................................................................... 9-32
Transmission Shaft Disassembly...................................................................................... 9-33
Transmission Shaft Assembly........................................................................................... 9-33
Shift Drum and Fork Removal........................................................................................... 9-37
Shift Drum and Fork Installation........................................................................................ 9-37
Shift Drum Disassembly.................................................................................................... 9-37
Shift Drum Assembly ........................................................................................................ 9-37
Shift Fork Bending ............................................................................................................ 9-38
Shift Fork/Gear Groove Wear ........................................................................................... 9-38
Shift Fork Guide Pin/Drum Groove Wear.......................................................................... 9-38
Gear Dog and Gear Dog Hole Damage............................................................................ 9-38
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