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9. Crankshaft / Crankcase / Transmission / Kick Starter
Precautions in Operation
General Information
z This Section concerns disassembly of the crankcase and transmission system for repair
purpose.
z The following components need to be removed before disassembling the crankcase.
Engine Chapter 6
Cylinder Head Chapter 7
Cylinder / Piston Chapter 8
Clutch / Oil Pump / Gear Shift Spindle Chapter 4
ACG / Starter Clutch / Starter Motor Chapter 5
z The crankshaft should be replaced as a unit if the timing sprocket on the crankshaft needs to
be replaced.
Specification Unit：mm
Item Standard Service Limit
Conrod big end side clearance 0.050~0.300 0.600
Conrod big end vertical clearance 0.004~0.012 0.050
Run-out
─
0.100
Crankshaft
Conrod small end inner diameter 15.010~15.028 15.080
Inner diameter 12.000~12.018 12.050
Gear shift fork
Claw thickness 4.930~5.000 4.700
Shift fork shaft Outer diameter 11.976~11.994 11.960
Kick starter spindle outer diameter 24.859~24.880 24.800
Kick starter
Kick starter pinion inner diameter 24.900~24.921 24.960
Torque Value
Crankcase bolt 0.8~1.2kgf-m
Cylinder / cylinder head bolt 0.7~1.0kgf-m
Engine oil drain bolt 1.5~2.5kgf-m
Cam chain tensioner bolt 0.8~1.2kgf-m
Special Tools
Inner bearing puller SYM-6204020
Bearing driver 6204 SYM-9110400
Bearing driver 6301 SYM-9610000
Bearing driver 6203/6004 SYM-9620000
9-3
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