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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 ............... 9-8
Crankcase Splitting............................ 9-9
Crankcase Splitting ...................... 9-9
Crankcase Assembly ................... 9-10
Crankshaft and Connecting Rods...... 9-15
Crankshaft Removal .................... 9-15
Crankshaft Installation ................. 9-15
Connecting Rod Removal ............ 9-15
Connecting Rod Installation ......... 9-16
Crankshaft/Connecting Rod
Cleaning .................................... 9-19
Connecting Rod Bend Inspection 9-20
Connecting Rod Twist Inspection. 9-20
Connecting Rod Big End Side
Clearance Inspection ................ 9-20
Connecting Rod Big End
Bearing Insert/Crankpin Wear
Inspection.................................. 9-21
Crankshaft Side Clearance
Inspection.................................. 9-22
Crankshaft Runout Inspection...... 9-23
Crankshaft Main Bearing
Insert/Journal Wear Inspection . 9-23
Balancer ............................................ 9-26
Balancer Removal........................ 9-26
Balancer Installation..................... 9-26
Balancer Adjustment.................... 9-27
Balancer Damper Inspection........ 9-27
Starter Motor Clutch .......................... 9-28
Starter Motor Clutch
Removal/Installation.................. 9-28
Starter Motor Clutch Inspection ... 9-28
Starter Motor Clutch Disassembly 9-28
Starter Motor Clutch Assembly .... 9-28
External Shift Mechanism.................. 9-29
Shift Pedal Removal .................... 9-29
Shift Pedal Installation ................. 9-29
External Shift Mechanism
Removal .................................... 9-30
External Shift Mechanism
Installation................................. 9-30
External Shift Mechanism
Inspection.................................. 9-31
Transmission ..................................... 9-33
Transmission Shaft Removal ....... 9-33
Transmission Shaft Installation .... 9-33
Transmission Shaft Disassembly. 9-33
Transmission Shaft Assembly...... 9-34
Shift Drum and Fork Removal...... 9-38
Shift Drum and Fork Installation... 9-38
Shift Drum Disassembly............... 9-38
Shift Drum Assembly ................... 9-38
Shift Fork Bending Inspection...... 9-39
Shift Fork/Gear Groove Wear
Inspection.................................. 9-39
Shift Fork Guide Pin/Drum
Groove Wear Inspection ........... 9-39
Gear Dog and Gear Dog Hole
Damage Inspection ................... 9-39
Ball Bearing, Needle Bearing, and Oil
Seal................................................. 9-40
Ball and Needle Bearing
Replacement............................. 9-40
Ball and Needle Bearing Wear
Inspection.................................. 9-40
Oil Seal Inspection ....................... 9-40
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