r
-.
l
CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER
SERVICE INFORMATION
GENERAL
• This section covers crankcase separation
fo
r service
of
the
crankshaft, transmission a nd balancer.
• The crankcase
must
be
separated
to
service
the
crankshaft
and
transmission.
• The engine
must
be
out
of
the
frame
for
this service.
• The
following
parts
must
be
removed before separating the crankcase.
- Clutch (page
11
-7)/sta
ter
clutch(page 11-1 9J/kickstarter (page 11-151/gearshift linkage (pa
ge
11-24)
- Cylinder head (page 9-24)
-
Cylinder
(page 10-5
)/pisto
n (page 10-6)
- Engine (page 8-5)
-
Flywheel (page
12
-5)
- Oil
pump
drive
gear/drive
pin
(page 5-7)
-
Starter
motor
(page
19-6)
- Drive
sprocket
(page 8-4)
SPECI
FICATIONS ('05 - '07)
IT
EM
STANDARD
Crankshaft
Side clearance 0.30
0.75 (0.0
12
0.030)
Radial
clearance
0.006
0.018 (0.0002
- 0.0007)
Runout R
-
L
-
Transmission
Gear
LO.
M4
28.007 - 28.028 (1.1026
1.1035)
M5
25.020 - 25.041 (0.9850 - 0.9859)
C1
22.007
22.028 (0.8664 0.8672)
C2
30.020
30.041
(1.1819
1.
1827)
C3
25.020 - 25.041 (0.9850 0.9859)
Bushing
0.0.
M4
27.959
27.980
(1.
1007 1.1016)
C2
29.979
30.000 (1.1803
1.1811)
Bushing
LD.
C2
27.000
27.021
(1.0630
1.0638)
Gear-to-bushing
M4
0.027 0.069 (0.0011
0.0027)
clearance
C2
0.020
0.062 (0.0008 0.0024)
Mainshaft
0.0
.
M5
24.959
24.980 (0.9826 0.9835)
Countershaft
0.0.
Cl
bearing
18.987 19.000 (0.7475
0.7480)
C2
bushing
26.959
26.980 (1.06
14
1.0622)
C3
24.959
24.980 (0.9826 0.9835)
Gear-to-shaft
M5
0.040
0.082 (0.0016 0.0032)
clearance
C3
0.040
0.082 (0.0016 - 0.0032)
Bushing-t
o·shaft
C2
0.020 - 0.062 (0.0008 - 0.0024)
clearance
Shift fork, shift Fork
ctaw
thickness
4.93
5.00 (0.194 - 0.197)
fork shaft
Shift fork 1
.0.
C
10.989
11.011
(0.4326 0.4335)
R,
L
12.035 -
12
.056 (0.4738 0.4746)
Fork
shaft
0.0.
C
10.969 - 10.980 (0.4319 0.4323)
R, L 11.966 11.984 (0.471'
0.4718)
Unit·
mm
(in)
SERVICE LIMIT
0.75 (0.030)
0.05 (0.002)
0.03 (0.001)
0.05 (0.002)
28.05
(1.
104)
25.07 (0.987)
22.04 (0.868)
30.07
(1.
184)
25.07 (0.987)
27.94(1.100)
29.95 (1.179)
27.04 (1.065)
0.
11
(0.004)
0.12 (0.005)
24.94 (0.982)
18.94
(0.746)
26.94 (1.061)
24.96 (0.983)
0.13 (0.005)
0.082 (0.0032)
0.12 (0.005)
4.8 (0.
19)
nOll
(0.4335)
12.070 (0.4752)
10.969 (0.4318)
11.950 (0.4705)
13-3
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