CRANKSHAFT/TRANSMISSION 12 N*m (1.
10 m SERVICE INFORMATION 12-1 CRANKSHAFT 12-3 TROUBLESHOOTING 12-2 TRANSMISSION 12-9 SERVICE INFORMATION GENERAL The crankcase must be separated t o service the crankshaft and transmission. Refer t o section 11 for crankcase separati on/assem bly. Be careful not t o damage the crankshaft main journal and journal bearing while removing or installing the crankshaft. Mark and store the disassembled parts t o ensure that they are installed in their original locations.
CRANKSHAFT/TRANSMISSION TORQUE VALUES Connecting rod bearing cap nut Crankcase 9 m m bolt (main journal bolt) 35 N * m (3.6 kgf-m, 26 Ibf-ft) See page 12-7 Apply oil to the threads and seating surface TOOLS Inner driver, 40 m m I.D.
CRANKSHAFT/TRANSMISSION CRANKSHAFT REMOVAL Separate the crankcase halves (page 11-3). Remove the connecting rod bearing cap nuts and bearing caps. Before removai pos tion a// the pistons a t TDC (Top Dead Center) to prevent damaging the crankpin with the connecting rod bolt threads Remove the crankshaft. .bR0 --9ie-*w M A I N IOlJRNAL BEARINGS I Remove the main journal bearings f r o m both the crankcases. Remove the crankshaft oil jets f r o m the upper crankcase.
PRIMARY DRWE SUB-GEAR REMOVAL FRICTION SPRING 3 SNA Remove the special snap ring and friction spring. Remove the primary drive sub-gear and springs. PRIMARY DRIVE SUB-GEAR INSTALLATION S U B-GEAR Install the springs into the primary drive gear as shown. Install the primary drive sub-gear onto the primary drive gear, aligning the holes between the gear. v ALIGN Apply molybdenum disulfide oil t o the area shown i n the illustration.
CRANKSHAFT/TRANSMISSlON Install the friction spring and new special snap ring. ~ NOTICE ~ You must use a n e w special snap ring. Using a snap ring other than specified or reusing the original snap ring can cause severe engine damage. FRICTION SPRING install a new special snap ring with its large tab facing t o the right and the chamfered side facing in. Make sure the new special snap ring end gap is aligned with the right angle of the crankshaft cutouts as shown.
CRANKSHAFT/TRANSMISSIQN If the special tool is not available, prepare a suitable collar, washer and 10 mm flange bolt (example; flywheel bolt) for the bearing installation. Assemble the above items, and screw the bolt gradually, until the new needle bearing is properly installed. INSPECTIQN CRANKSHAFT RUNOUT Support the crankshaft o n both ends. Set a dial indicator on the center main journal o f the crankshaft. Rotate the crankshaft t w o revolutions and read runout at the center journal.
CRANKSHAFT/TRANSMISSION Assemble the crankcase halves. PLASTIC REGION TLGHTENING METHOD: Install the removed main journal 9 m m bolts. Tighten the main journal 9 m m bolts as follow: Tighten the 9 m m bolts in numerical order i n the illustration t o the following torque. TORQUE: 10 N - m (1.0 kgf-m, 7 Ibf-ft) Retighten the 9 mrn bolts in the same order above to the following torque. TORQUE: 20 N - m (2.0 kgf-m, 14 Ibf-ft) Further tighten the 9 m m bolts 150 degrees.
The numbers (0, 1. 2 or31 on the crank weiaht are the codes mainlourna’ 0 D s from /eft to right Record the corresponding main journal O.D. code numbers from the crank weight. Cross reference the case and journal codes t o determine the replacement bearing color codes. CODE BEARING THICKNESS: B (Brown): Thick C (Green): D (Yellow): E (Pink): F (Red): G (White): Thin IDENTIFICATION COLOR I After selecting new bearings, recheck the clearance with a plastigauge.
CRANKSHAFT/TRANSMISSlON The bearing tabs should be abgned with the grooves in the case. Before instaaiiation, posmon a// the pistons at TDC (Top Dead Center) to prevent damaging the crankpin with the connecting rod threads Install the main journal bearings into the upper and lower crankcase. Apply 'molybdenum disulfide oil t o the upper and lower main journal bearings. Install the crankshaft. Install the connecting rod bearing caps.
CRANKSHAFT/TRANSMISSlON Remove the dowel pins and countershaft bearing set ring. Disassemble the mainshaft and countershaft. Check the gear dogs, dog holes and teeth for abnormal wear or lack of lubrication. Measure the I.D. of each gear. SERVICE LIMITS: M5, M6: 31.04 mm 1.222 in) c1: 26.04 mm 1.025 in) C2, C3, C4: 33.04 mm 1.301 in) Measure the I.D. and O.D. of each gear bushing. SERVICE LIMITS: O.D.: M5, M6: C3, C4: I.D.: M5: c2: 30.93 mm (1.218 in) 32.93 mm (1.296 in) 28.02 mm (1.103 in) 30.02 rnm (1.
CRANKSHAFT/TRANSMISSION Measure the O.D. of the mainshaft and countershaft. M5 SERVICE LIMITS: M5: 27.957 mm (1.1007 in) Clutch outer guide: 24.96 mm (0.983 in) c2: 29.96 mm (1.180 in) CLUTCH OUTER GUIDE c2 Do not try to remove the countershaft bearing from the shaft if the bearing is worn or damaged, replace the countershaft as an assembiy. BEARING REPLACEMENT Turn the outer race of each bearing with your finger. The bearings should turn smoothly and quietly.
CRANKSHAFT/TRANSMISSION ASSEMBLY M2 GEAR (15T) M6 GEAR (21T) M3/4 GEAR (20120T) M5 GEAR (21T) -=Q$ I MAINSHAFT/MI GEAR (13T) COUNTERSHAFT 12-12
CRANKSHAFT/TRANSMISSlON , II U Assemble the transmission gear and shafts. Coat each gear with clean engine oil and check for smooth movement. Apply molybdenum disulfide oil to the shift fork grooves in the M3/4, C5 and C6 gear. INSTALLATION Install the dowel pins in the upper crankcase holes. Install the countershaft bearing set ring into the upper crankcase groove.
CRANKSHAFT/TRANSMISSION Install the mainshaft and countershaft b y aligning the countershaft bearing groove w i t h the set ring on t h e crankcase, and aligning the bearing cap holes w i t h the dowel pins. Also align the countershaft bearing stopper pin w i t h the groove in the crankcase. Assemble the crankcase (page 11-12).
