Crankshaft Kick Starter Transmission Service Manual

11. CRANKSHAFT/KICK STARTER/TRANSMISSION
LOCK
G
CK
LO
11
LOCK
11-0
CRANKSHAFT/KICK STARTER/TRANSMISSION
System Diagram
Service Information/Specifications
Special Tools
Troubleshooting
Crankcase Separation
Crankshaft Removal
Kick starter Removal
11-0
11-1
11-2
11-3
11-4
11-6
11-9
Transmission Removal
Transmission Assembly
Transmission Installation
Crankshaft Installation
Kick starter Installation
Crankcase Assembly
11-11
11-18
11-20
11-21
11-21
11-22
SERVICE INFORMATION
GENERAL
• The crankcase must be separated to service the crankshaft, transmission and kick starter.
• The engine must be removed from the frame to separate the crankcase.
• The following components must be removed before separating the crankcase:
- Flywheel (page 10-5)
- Cylinder head (page 7-4)
- Cylinder/piston (page 8-3)
- Oil pump (page 4-3)
- Clutch (page 9-7)
- Gearshift linkage (page 9-15)
- Primary drive gear( page 9-9)
- Neutral switch (page 17-5)
- Kick starter (page 11-9)
• Be careful not to damage the crankcase mating surfaces when servicing.
SPECIFICATIONS
Unit: mm
CRANKSHAFT/KICK STARTER/TRANSMISSION
ITEM
Shift fork
10.000-10.018
10.017
Claw thickness
4.93-5.00
4.90
Shaft O.D
9.986-9.995
9.93
Left
23.959-23.980
23.94
Right
27.959-27.980
27.94
Left
24.000-24.033
24.05
Right
28.000-28.021
28.04
M3
17.000-17.018
17.06
C4
20.000-20.021
20.06
M2
17.000-17.018
17.06
C1
18.000-18.018
18.06
Bushing O.D
C1
17.966-17.984
17.92
Bushing I.D
C1
15.000-15.018
15.04
Gear to bushing clearance
C1
0.016-0.052
0.09
At M3
16.966-16.984
16.95
At M2
16.966-16.984
16.95
Shift drum
Journal I.D
Gear I.D
Mainshaft O.D
11-1
SERVICE LIMIT
I.D
O.D
Transmission
STANDARD
CRANKSHAFT/KICK STARTER/TRANSMISSION
CRANKSHAFT/KICK STARTER/TRANSMISSION
STANDARD
ITEM
SERVICE LIMIT
At C1
14.966-14.984
14.95
At C4
19.959-19.980
19.94
M3
0.016-0.052
0.09
M2
C4
0.016-0.052
0.09
0.020-0.062
0.10
C1
0.016-0.052
0.090
-
0.10
0.60
Big and radial clearance
0.10-0.35
-
Pinion I.D
20.000-20.021
20.08
Spindle O.D
19.959-19.980
19.94
Shaft gear reduction
O.D
8.972-8.987
8.92
Gear starter reduction
I.D
9.000-9.022
9.06
Countershaft O.D
Transmission
Gear to shaft clearance
Bushing-to-shaft clearance
Run out
Big end side clearance
Crankshaft
Kick starter
0.05
11
SPECIAL TOOLS
COUNTERSHAFT OIL SEAL GUIDE
PART NO: 070 HH KTC 009
COLLET BEARING REMOVER, 12 mm
PART NO: 070 HH 198 026
UNIVERSAL BEARING PULLER
PART NO: 070 HH 198 009
CRANKCASE BRG REMOVER SHAFT
PART NO: 070 HH KFN 006
CRANKSHAFT BEARING (RHS)
PULLER CUM INSTALLER
PART NO: 070 HH KTC 005
CRANKCASE BRG REMOVER WEIGHT
PART NO: 070 HH KFN 007
DRIVER OUTER, 32x35 mm
PART NO: 070 HH KFN 010
HANDLE BEARING DRIVER
PART NO: 070 HH KFN 008
PILOT DRIVER, 12 mm
PART NO: 070 HH KFN 012
DRIVER OUTER, 40x46 mm
PART NO: 070 HH 198 031
DRIVER OUTER, 24x27 mm
PART NO: 070 HH KFN 021
PILOT DRIVER, 17 mm
PART NO: 070 HH 198 033
CRANKSHAFT BEARING COLLAR
PART NO: 070 HH KZA 001
DRIVE SHAFT INSTALLER EXTENSION
PART NO: 070 HH KZN 001
CRANKSHAFT BEARING (LHS)
INSERTER
PART NO: 070 HH KTN 007
11-2
CRANKSHAFT/KICK STARTER/TRANSMISSION
TROUBLE SHOOTING
Excessive noise
• Worn, sized or chipped transmission gear
• Worn or damaged transmission bearing
• Worn or damaged connecting rod bearing
• Worn crankshaft bearing
• Worn connecting rod small end
Hard to shift
• Bent shift fork
• Bent shift fork shaft
• Damaged shift drum guide groove
• Damaged shift fork guid pin
• Improper clutch operation
Transmission jumps out of gear
• Worn gear dogs or slots
• Worn shift drum guide groove
• Worn shfit fork guide pin
• Worn shift fork groove in gear
• Worn shift fork shaft
• Bent fork shaft
• Worn cylinder or piston rings
• Improper installation of piston rings
11-3
CRANKSHAFT/KICK STARTER/TRANSMISSION
O-RING
CRANKCASE SEPARATION
Remove the engine from the frame (page 6-2).
Refer to service information (page 11-1) for removal of
necessary components before disassembling the crankcase.
Remove the A.C. Generator (page 10-2).
Remove the neutral lamp switch mounting bolts.
Remove the neutral lamp switch and O-ring.
MOUNTING BOLTS
SPRING
NEUTRAL LAMP SWITCH
Remove the contact cap and the spring.
11
CONTACT CAP
CAM CHAIN TENSIONER MOUNTING BOLT
Remove the cam chain tensioner set plate by removing its
mounting bolt.
Remove the cam chain tensioner and cam chain.
CAM CHAIN SET PLATE
CAMCHAIN TENSIONER
CAMCHAIN TENSIONER INSPECTION
Check the camchain tensioner for wear or damage.
11-4
CRANKSHAFT/KICK STARTER/TRANSMISSION
PUSH PLUG PLATE
Remove the bolt and the push plug plate.
BOLT
SET PLATES
PUSH PLUG
Remove spring and the push plug.
Remove the bearing set plate bolts and set plates.
NOTE
The set plates hold the crankshaft and should be removed
before removing the crankcase bolts.
BOLTS
SPRING
Loosen the crankcase bolts in 2 or 3 steps in a criss-cross
pattern.
Remove the crankcase bolts.
Place the right crankcase downwards.
Install the oil seal guide on countershaft till it seats inside the
oil seal.
COUNTERSHAFT OIL SEAL GUIDE
PART NO: 070 HH KTC 009
Carefully separate the left crankcase from the right
crankcase as shown in the figure. If required top them at
several locations with a mallet.
NOTE
• Do not split crankcase using sharp tool.
• If the engine is dismantled on the engine jig, then
remove the left crankcase mounting bolts and remove
the left crankcase. Do not remove the right crankcase
mounting bolts.
• Never handle the crankcase by holding the studs.
BOLTS
LEFT CRANKCASE
OIL SEAL GUIDE
RIGHT CRANKCASE
11-5
CRANKSHAFT/KICK STARTER/TRANSMISSION
Remove the dowel pins.
Clean of the sealant from left and right crankcase mating
surface.
DOWEL PINS
CRANKSHAFT REMOVAL
CRANKSHAFT
CAUTION
When removing, inspecting and installing the crankshaft,
be careful not to damage or kink crank web.
Remove the crankshaft from the right crankcase.
11
RIGHT CRANKCASE
CRANKSHAFT BEARING REMOVAL
UNIVERSAL BEARING PULLER
LEFT CRANKSHAFT BEARING
The left crankshaft bearing is press fitted on the crankshaft.
Remove it using a special tool as shown in the figure.
UNIVERSAL BEARING PULLER
PART NO: 070 HH 198 009
CRANKSHAFT
LEFT CRANKSHAFT BEARING
RIGHT CRANKSHAFT BEARING
RIGHT CRANKCASE
RIGHT CRANKSHAFT BEARING
The right crankshaft bearing is press fitted on the right
crankcase.
Remove it using a special tool as shown in the figure.
CRANKSHAFT BEARING (RHS)
PULLER CUM INSTALLER
PART NO: 070 HH KTC 005
CRANKSHAFT BEARING (RHS) PULLER CUM INSTALLER
11-6
CRANKSHAFT/KICK STARTER/TRANSMISSION
BEARING
BEARING REPLACEMENT
INSPECTION
Turn the inner race of each bearing with your finger. The
bearing should turn smoothly and quietly.
Also check that the bearing inner race fits tightly in the
crankshaft.
Remove and discard the bearing, if the race does not turn
smoothly, quietly, or fits loosely in the crankcase.
NOTE
• Do not rotate the bearing races when dry.
• Always clean and lubricate the bearing before rotation.
CRANKSHAFT INSPECTION
BIG END SIDE CLEARANCE
CRANKSHAFT
CRANKSHAFT
Measure the connecting rod big end side clearance with a
feeler gauge.
SERVICE LIMIT
BIG END SIDE CLEARANCE: 0.60 mm
BIG END RADIAL CLEARANCE
Measure the connecting rod big end radial clearance at two
different points across from each other as shown.
SERVICE LIMIT
CONNECTING ROD
BIG END RADIAL CLEARANCE: 0.05 mm
CRANKSHAFT
CRANKSHAFT RUN OUT
Place the crankshaft on a stand or V-blocks and measure the
run-out using a dial gauge.
Set the dial indicator on the shafts.
Rotate the crankshaft two revolutions and read the run out.
Actual run-out is ½ of Total Indicator Reading (TIR).
SERVICE LIMIT
CRANKSHAFT RUN OUT: 0.10 mm
TIMING SPROCKET
CRANK PIN
TIMING SPROCKET
REPLACEMENT/INSTALLATION
Check the timing sprocket teeth for wear or damage.
Remove the timing sprocket if necessary.
While installing the timing sprocket, aligning the root
between two teeth with the key way in the crankshaft.
NOTE
If the timing sprocket teeth are worn or damaged, check the
cam chain, tensioner and cam sprocket.
WOODRUFF KEY
11-7
CRANKSHAFT/KICK STARTER/TRANSMISSION
BEARING
CRANKSHAFT BEARING
INSTALLATION
The left crankshaft bearing is press fitted on the crankshaft.
Apply clean engine oil to the new left crankshaft bearing.
Install the left crankshaft bearing using the following tools as
shown in the image.
CRANKSHAFT BEARING (LHS) INSERTER
PART NO: 070 HH KTN 007
CRANKSHAFT BEARING COLLAR
PART NO: 070 HH KZA 001
DRIVE SHAFT INSTALLER EXTENSION
PART NO: 070 HH KZN 001
Insert the spacer to the crankshaft using the arbor press and
special tools as shown in figure.
CRANKSHAFT BEARING COLLAR
PART NO: 070 HH KZA 001
11
SPACER
Insert the timing sprocket to the crankshaft using the arbor
press and special tools as shown in figure.
CRANKSHAFT BEARING COLLAR
PART NO: 070 HH KZA 001
CAUTION
Use soft wooden block to seat the crankcase.
TIMING SPROCKET
RIGHT CRANKSHAFT BEARING
RIGHT CRANKCASE
The right crankshaft bearing is press fitted on the right
crankcase. Install is using a special tool as shown in the
figure.
CRANKSHAFT BEARING (RHS) PULLER CUM
INSTALLER
PART NO: 070 HH KTC 005
CRANKSHAFT BEARING (RHS) PULLER CUM INSTALLER
11-8
CRANKSHAFT/KICK STARTER/TRANSMISSION
KICK STARTER
REMOVAL
Remove the kick starter spring (page 9-18).
Separate the crankcase (page 11-4).
Remove the kick starter spindle from the right crankcase.
KICK STARTER SPINDLE
FRICTION SPRING
CIRCLIP
DISASSEMBLY
Remove the thrust washer and circlip.
Remove the kick starter ratchet and friction spring from the
kick starter spindle.
STARTER RATCHET
KICK STARTER SPINDLE
THRUST WASHER
KICK STARTER PINION
WASHER CIRCLIP
KICK STARTER PINION
Take out the circlip, thrust washer and the kick starter pinion
gear from the kick starter spindle.
NOTE
Do not expand the circlip more than necessary.
INSPECTION
Check the following:
- Starter ratchet and kick stater pinion for excessive wear or
damage.
- Spindle for bend or damage.
- Check the friction spring for fatigue.
- Gear teeth of the pinion for wear or damage.
- Sliding surfaces of the pinion and spindle for wear, scoring
or damage.
Measure the starter pinion I.D.
O.D
SERVICE LIMIT
STARTER PINION I.D: 20.08 mm
Measure starter spindle O.D at pinion sliding porting.
I.D
SERVICE LIMIT
STARTER SPINDLE O.D: 19.94 mm
KICK STARTER SPINDLE
11-9
CRANKSHAFT/KICK STARTER/TRANSMISSION
ASSEMBLY
CORRECT
INCORRECT
Assembly is in the reverse order of removal.
SNAP RING
STARTER RATCHET
THURST WASHER
FRICTION SPRING
11
CIRCLIP
WASHER
KICK STARTER PINION
KICK STARTER SPINDLE
11-10
CRANKSHAFT/KICK STARTER/TRANSMISSION
SHIFT FORK SHAFT
TRANSMISSION
REMOVAL
Separate the crankcase (page 11-4).
Remove the kick starter spindle (page 11-9).
Remove the crankshaft (page 11-6).
Remove the shifter fork shaft from the shift forks.
Remove the shift forks and shift drum.
Remove the mainshaft and countershaft as a set.
LEFT SHIFT FORK
RIGHT SHIFT FORK
COUNTERSHAFT
SHIFT DRUM
MAINSHAFT
MAINSHAFT
TRANSMISSION DISASSEMBLY
Disassemble the mainshaft and countershaft.
NOTE
• Keep track of the disassembled parts (gears, bushings,
washers and circlips) by stacking them on a tool or
slipping them onto a piece of wire.
• Do not expand the snap ring more than necessary for
removal. To remove snap ring, expand the snap ring
and pull it off using the gear behind it.
COUNTERSHAFT
11-11
CRANKSHAFT/KICK STARTER/TRANSMISSION
INSPECTION
TRANSMISSION GEAR
Check the gear dog- teeth, dog-slots and teeth for abnormal
wear or lack of lubrication.
Measure the I.D of each gear.
SERVICE LIMIT
M2, M3: 17.06 mm
M2
M3
SERVICE LIMIT
C1: 18.06 mm
C4: 20.06 mm
C1
BUSH
11
C4
I.D
Check the bush for wear or damage.
Measure the O.D and I.D of C1 gear bushing.
SERVICE LIMIT
I.D (C1): 15.04 mm
O.D (C1): 17.92 mm
Measure the gear to bushing clearance.
SERVICE LIMIT
C1: 0.09 mm
O.D
MAINSHAFT/COUNTERSHAFT
Check the groves and sliding sufraces for damage or
abnormal wear.
Measure the O.D of the mainshaft and countershaft at the
gear sliding areas.
C1 bushing
SERVICE LIMIT
At M2, M3 gear: 16.95 mm
At C1 gear bush: 14.95 mm
At C4 gear: 19.94 mm
Calculate the bushing to shaft clearance by subtracting
countershaft O.D from gear bushing I.D.
SERVICE LIMIT
C1: 0.09 mm
C4
M2
M3
11-12
CRANKSHAFT/KICK STARTER/TRANSMISSION
SHIFT FORK
I.D
Check the shift fork for deformation or abnormal wear.
Check the shift fork guide pin for abnormal wear or damage.
Measure the shift form claw thickness.
SERVICE LIMIT
SHIFT FORK CLAW THICKNESS: 4.90 mm
Measure the shift fork I.D.
SERVICE LIMIT
CLAW THICKNESS
SHIFT FORK I.D: 10.7 mm
SHIFT FORK SHAFT
Check the shift fork shaft for damage or straightness.
Measure the shift fork shaft O.D.
SERVICE LIMIT
SHIFT FORK SHAFT O.D: 9.93 mm
SHIFT DRUM INSPECTION
Inspect the shift drum for scoring, scratches or evidence of
insufficient lubrication.
Check the shift drum grooves for wear or damage.
Measure the shift drum O.D at each end.
R
SERVICE LIMIT
SHIFT DRUM O.D (LHS): 23.94 mm
SHIFT DRUM O.D (RHS): 27.94 mm
L
Check the shift drum journals on the left crankcase for
excessive wear or damage.
Measure the shift drum journal I.D.
SERVICE LIMIT
SHIFT DRUM JOURNAL I.D (LHS): 24.05 mm
11-13
I.D
CRANKSHAFT/KICK STARTER/TRANSMISSION
Check the shift drum journals on the right crankcase for
excessive wear or damage.
Measure the shift drum journal I.D.
SERVICE LIMIT
SHIFT DRUM JOURNAL I.D (RHS): 28.04 mm
I.D
RIGHT CRANKCASE
BEARING INSPECTION
Turn the inner race of each bearing with your finger.
The bearing should turn smoothly and quietly.
Also check that bearing outer races fit tightly in the
crankcases.
Replace the bearings if necessary.
NOTE
• Do not rotate the bearing races when dry.
• Always clean and lubricate the bearing before rotation.
LEFT CRANKCASE MAINSHAFT BEARING
REMOVAL
11
BEARING
BEARING REMOVER WEIGHT
Drive out the mainshaft bearing from the left crankcase by
using the following special tools.
Insert the collet in the bearing inner race.
Locate the bearing remover shaft and weight in the collet.
Tighten the remover shaft by holding the collet firmly till the
collet lips lock on to the inner race of the bearing. Holding
the remover shaft, slide the weight upwards with force. The
bearing will come off its seat. Loosen the remover shaft from
the collet and remove the bearing.
COLLET BEARING REMOVER, 12 mm
PART NO: 070 HH 198 026
CRANKCASE BRG REMOVER SHAFT
PART NO: 070 HH KFN 006
CRANKCASE BRG REMOVER WEIGHT
PART NO: 070 HH KFN 007
BEARING REMOVER SHAFT
COLLET
COUNTERSHAFT OIL SEAL
LEFT CRANKCASE COUNTERSHAFT
BEARING REMOVAL
Remove the countershaft oil seal and gear shift spindle oil
seal from the left crankcase.
GEARSHIFT SPINDLE OIL SEAL
11-14
CRANKSHAFT/KICK STARTER/TRANSMISSION
HANDLE BEARING DRIVER
Drive out the countershaft bearing from the left crankcase
with following tools.
HANDLE BEARING DRIVER
PART NO: 070 HH KFN 008
DRIVER OUTER, 24x27 mm
PART NO: 070 HH KFN 010
PILOT DRIVER, 17 mm
PART NO: 070 HH 198 033
DRIVER OUTER
SET PLATE
PILOT DRIVER
SET PLATE BOLTS
RIGHT CRANKCASE MAINSHAFT
BEARING REMOVAL
Remove the bolts and mainshaft bearing set plate.
Drive out the mainshaft bearing from the right crankcase.
HANDLE BEARING DRIVER
HANDLE BEARING DRIVER
PART NO: 070 HH KFN 008
DRIVER OUTER, 32x35 mm
PART NO: 070 HH KFN 010
PILOT DRIVER, 17 mm
PART NO: 070 HH 198 033
RIGHT CRANKCASE COUNTERSHAFT
BEARING
REMOVAL
DRIVER OUTER
PILOT DRIVER
HANDLE BEARING DRIVER HANDLE BEARING DRIVER
Drive out the countershaft bearing from the right crankcase.
Drive out the mainshaft bearing from the right crankcase.
HANDLE BEARING DRIVER
PART NO: 070 HH KFN 008
DRIVER OUTER, 24x27 mm
PART NO: 070 HH KFN 021
PILOT DRIVER, 12 mm
PART NO: 070 HH KFN 012
PILOT DRIVER
11-15
DRIVER OUTER/PILOT DRIVER
CRANKSHAFT/KICK STARTER/TRANSMISSION
DRIVER OUTER
HANDLE BEARING DRIVER
INSTALLATION
To install the bearings onto the crankcase, set the required
driver outer and pilot to the driver handle as shown and drive
in the bearing.
NOTE
Make sure not to push the ball or the inner race of the
bearing. Make sure not to damage the rolling surface of
the bearing at this time.
Lubricate the all bearings with engine oil.
Drive new bearings into the left crankcase with following
tools.
PILOT DRIVER
HANDLE BEARING DRIVER
LEFT CRANKCASE MAINSHAFT BEARING
INSTALLATION
Lubricate all the bearings with clean engine oil.
Drive new mainshaft bearing into the left crankcase.
HANDLE BEARING DRIVER
PART NO: 070 HH KFN 008
DRIVER OUTER, 24x27 mm
PART NO: 070 HH KFN 021
PILOT DRIVER, 12 mm
PART NO: 070 HH KFN 012
11
DRIVER OUTER
PILOT DRIVER
HANDLE BEARING DRIVER
LEFT CRANKCASE COUNTERSHAFT
BEARING INSTALLATION
Drive new countershaft bearing into the left crankcase.
HANDLE BEARING DRIVER
PART NO: 070 HH KFN 008
DRIVER OUTER, 40x46 mm
PART NO: 070 HH 198 031
PILOT DRIVER, 17 mm
PART NO: 070 HH 198 033
Apply grease to new oil seal lips.
Install counter shaft and gearshift spindle oil seals.
DRIVER OUTER/PILOT DRIVER
Drive to case
end face
GEAR SHIFT
SPINDLE
OIL SEAL
0.5-1.0 mm
COUNTERSHAFT
OIL SEAL
11-16
CRANKSHAFT/KICK STARTER/TRANSMISSION
HANDLE BEARING DRIVER
RIGHT CRANKCASE MAINSHAFT
BEARING INSTALLATION
Drive new mainshaft bearing into the right crankcase.
HANDLE BEARING DRIVER
PART NO: 070 HH KFN 008
DRIVER OUTER, 40x46 mm
PART NO: 070 HH 198 031
PILOT DRIVER, 17 mm
PART NO: 070 HH 198 033
DRIVER OUTER
PILOT DRIVER
LOCK
SET PLATE BOLTS
Apply locking agent to the threads of the set plate bolt.
Install the set plate and bolts.
Tighten the bolts to the specified torque.
TORQUE
SET PLATE BOLT: 1.2 kgf-m
RIGHT CRANKCASE COUNTERSHAFT
BEARING INSTALLATION
HANDLE BEARING DRIVER
Drive new countershaft bearing into the right crankcase.
HANDLE BEARING DRIVER
PART NO: 070 HH KFN 008
DRIVER OUTER, 32x35 mm
PART NO: 070 HH KFN 010
PILOT DRIVER, 12 mm
PART NO: 070 HH KFN 012
PILOT DRIVER
11-17
DRIVER OUTER
CRANKSHAFT/KICK STARTER/TRANSMISSION
TRANSMISSION
ASSEMBLY
Clean all parts in high flash point solvent.
Apply clean engine oil to each gear teeth.
Apply molybdenum oil solution to the bush sliding surface to
ensure initial lubrication.
Assemble all parts into their original positions.
GEAR
CIRCLIP
THRUST LOAD
: Each gear teeth
THRUST WASHER
: Bush, free gear
NOTE
• Check the gears for freedom of movement or rotation
on the shaft.
• Install the thrust washers and circlip with the chamfered
side facing away from the thrust load side. Confirm the
inner side of circlip and thrust washer when you detect
the chamfered side.
• Do not reuse worn circlip which could easily spin in the
groove.
• Check that the circlips are seated in the grooves and
align their end gaps with the grooves of the spline.
CORRECT
INCORRECT
11
CIRCLIP
11-18
CRANKSHAFT/KICK STARTER/TRANSMISSION
: Each gear teeth
: Bush, free gear
MAINSHAFT
MAINSHAFT M1 GEAR (13T)
M3 GEAR (21T)
M4 GEAR (23T)
CIRCLIP
SPLINE WASHER
LOCK WASHER
SPLINE WASHER
CIRCLIP
COUNTERSHAFT
M2 GEAR (20T)
LOCK WASHER
THRUST WASHER
CIRCLIP
C4 GEAR (21T)
C2 GEAR (30T)
CIRCLIP
C1 BUSHING
C1 GEAR (36T)
C3 GEAR (36T)
SPLINE WASHER
SPLINE WASHER
COUNTERSHAFT
11-19
CRANKSHAFT/KICK STARTER/TRANSMISSION
MAINSHAFT
TRANSMISSION
INSTALLATION
Apply clean engine oil to the following parts:
- Mainshaft
- Countershaft
- Transmission gears
- Mainshaft bearing
- Shift drum O.D
Assemble the mainshaft, countershaft as shown.
COUNTERSHAFT
COUNTERSHAFT
MAINSHAFT
Install the mainshaft and countershaft as on assembly into
the right crankcase.
NOTE
• Do not forget to install the transmission end washer.
• During mainshaft and countershaft installaton, be
careful not to damage the countershaft oil seal.
11
NOTE
Each shift fork has a identification mark; “L” is for the left
shift fork, “R” is for the right shift fork.
Apply clean engine oil to the shift drum journal surface.
Install the shift drum onto the right crankcase.
“R” MARK
LEFT SHIFT FORK
“L” MARK
Install the right shift fork into the C3 shifter groovers with its
mark facing up (left crankcase side).
Install the left shift fork into the M4 shifter groove with its
mark facing up (left crankcase side).
Install the shift drum aligning the guide pins on the shift fork
with the guide grooves of the shift drum.
RIGHT SHIFT FORK
SHIFT DRUM
11-20
CRANKSHAFT/KICK STARTER/TRANSMISSION
SHIFT FORK SHAFT
Apply clean engine oil solution to the shift fork shaft.
Install the shift fork shaft.
CRANKSHAFT
CRANKSHAFT
INSTALLATION
Apply clean engine oil to bearing sliding surfaces and install
the crankshaft into the right crankcase.
RIGHT CRANKCASE
FRICTION SPRING
KICK STARTER
INSTALLATION
Install the kick starter spindle aligning the friction spring with
the groove in the left crankcase as shown.
KICK STARTER SPINDLE
GROOVE
Check the shift drum and crankshaft for smooth operation.
SHIFT DRUM
11-21
CRANKSHAFT/KICK STARTER/TRANSMISSION
CRANKCASE ASSEMBLY
Clean the crankcase mating surface thoroughly, being
careful not to damage them.
NOTE
• Dress the surface with an oil stone if necessary to
correct any minor roughness or irregularities.
• After cleaning, lubricate the crankcase bearings and
other contacting surfaces with clean engine oil.
Install the dowel pins onto the right crankcase.
DOWEL PINS
Apply a light but thorough coating of sealant to all
crankcase mating surface except the oil passage area.
NOTE
Apply “Three-bond 1215” or equivalent.
SEAL
11
COUNTERSHAFT OIL SEAL GUIDE
Install the left crankcase over the right crankcase.
CAUTION
Do not farce crankcase halves together: if there is
excessive force required, something is wrong. Remove the
right crankcase and check for misaligned parts.
NOTE
Use counter shaft oil seal guide while installing the
crankcase.
COUNTERSHAFT OIL SEAL GUIDE
PART NO: 070 HH KTC 009
LEFT CRANKCASE
RIGHT CRANKCASE
Install and tighten the crankcase bolts in a criss- cross pattern
in 2 or 3 steps.
BOLTS
11-22
CRANKSHAFT/KICK STARTER/TRANSMISSION
PUSH PLUG
PUSH PLUG PLATE
Install the bearing set plates. Install the three bolts holding
the set plates.
Install the push plug, spring, push plug plate and bolt.
NOTE
• Apply molybdenum oil solution to the tapered surface
of push plug to ensure initial lubrication.
• Apply locking agent to the push plug plate bolt.
SPRING
SET PLATE
CAM CHAIN TENSIONER
BOLT LOCK
MOUNTING BOLT
Install the cam chain onto the crankshaft timing sprocket.
Install the cam chain tensioner.
Install the cam chain tensioner set plate and tighten the bolt
securely.
CAM CHAIN
SPRING
SET PLATE
Install the spring and the contact cap.
CONTACT CAP
O-RING
Install a new O-ring to neutral lamp switch.
Install the neutral switch and tighten the mounting bolts.
Refer to service information (page 11-1) and install all
removed components back to crankcase.
Install the engine on the frame (page 6-6).
NEUTRAL LAMP SWITCH
11-23
MOUNTING BOLTS