CRANKSHAFT/TRANSMISSION

SYSTEM COMPONENTS
CRANKSHAFT/TRANSMISSION

12 N·m (1.2 kgf·m,

9 lbf·ft)

12 N·m (1.2 kgf·m,

9 lbf·ft)

10 N·m (1.0 kgf·m,

7 lbf·ft)

11-2
 CRANKSHAFT/TRANSMISSION
SERVICE INFORMATION
GENERAL
• The following components must be removed before separating the crankcase:
– engine (page 6-4)
– flywheel (page 10-6)
– cylinder head (page 7-6)
– cylinder/piston (page 8-4)
– oil pump (page 4-4)
– clutch (page 9-8)
– gearshift linkage (page 9-15)
– kickstarter idle gear (page 9-17)
– kickstarter (page 9-18)
– primary drive gear/crankshaft collar (page 9-21)
– neutral switch (page 17-13)
• Be careful not to damage the crankcase mating surfaces when servicing.

SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Crankshaft Runout – 0.03 (0.001)
Connecting rod big end radial clear- 0 – 0.008 (0 – 0.0003) 0.05 (0.002)
ance
Connecting rod big end side clear- 0.10 – 0.35 (0.004 – 0.014) 0.80 (0.032)
ance
Transmission Gear I.D. M4, M5 20.000 – 20.021 (0.7874 – 0.7882) 20.05 (0.789)
C1 20.500 – 20.521 (0.8071 – 0.8079) 20.55 (0.809)
C2 23.020 – 23.041 (0.9063 – 0.9071) 23.07 (0.908)
C3 23.025 – 23.046 (0.9065 – 0.9073) 23.07 (0.908)
Bushing O.D. M4, M5 19.959 – 19.980 (0.7858 – 0.7866) 19.91 (0.784)
C1 20.459 – 20.480 (0.8055 – 0.8063) 20.41 (0.804)
C2, C3 22.984 – 23.005 (0.9049 – 0.9057) 22.95 (0.904)
Gear-to-bushing M4, M5, C1 0.020 – 0.062 (0.0008 – 0.0024) 0.10 (0.004)
clearance C2 0.015 – 0.057 (0.0006 –0.0022) 0.10 (0.004)
C3 0.020 – 0.062 (0.0008 – 0.0024) 0.10 (0.004)
Bushing I.D. M4, C1 17.000 – 17.018 (0.6693 – 0.6700) 17.04 (0.671)
C2, C3 20.020 – 20.041 (0.7882 – 0.7890) 20.07 (0.790)
Mainshaft / coun- M4, C1 16.966 – 16.984 (0.6680 – 0.6687) 16.93 (0.667)
tershaft O.D. C2 19.978 – 19.989 (0.7865 – 0.7870) 19.94 (0.785)
C3 19.979 – 20.000 (0.7866 – 0.7874) 19.94 (0.785)
Bushing-to-shaft M4, C1 0.016 – 0.052 (0.0006 – 0.0020) 0.10 (0.004)
clearance C2 0.031 – 0.063 (0.0012 – 0.0025) 0.10 (0.004)
C3 0.020 – 0.062 (0.0008 – 0.0024) 0.10 (0.004)
Shift fork, Shift fork shaft O.D. 9.986 – 9.995 (0.3931 – 0.3935) 9.93 (0.391)
shift fork Shift fork I.D. 10.000 – 10.018 (0.3937 – 0.3944) 10.05 (0.396)
shaft Shift fork claw thickness 4.93 – 5.00 (0.194 – 0.197) 4.50 (0.177)

TORQUE VALUE
Mainshaft bearing setting plate bolt 12 N·m (1.2 kgf·m, 9 lbf·ft) Apply locking agent to the threads.
Crankshaft bearing retainer plate bolt 12 N·m (1.2 kgf·m, 9 lbf·ft)
Push plug bolt 10 N·m (1.0 kgf·m, 7 lbf·ft) Apply locking agent to the threads.

11-3
CRANKSHAFT/TRANSMISSION
TOOLS
Remover head, 12 mm Remover shaft, 12 mm Remover weight
070MC-KPLI410 070MC-KPLI420 070MC-KPLI300

Driver Pilot, 12 mm Pilot, 14 mm

070GD-001I100 070GD-004I130 07746-0041200

Pilot, 15 mm Pilot, 17 mm Pilot, 20 mm

07746-0040300 070GD-004I150 070GD-004I160

Pilot, 30 mm Attachment, 22 x 24 mm Attachment, 32 x 35 mm

07746-0040700 07746-0010800 070GD-002I140

11-4
 CRANKSHAFT/TRANSMISSION
Attachment, 37 x 40 mm Attachment, 42 x 47 mm Attachment, 52 x 55 mm
070GD-002I150 070GD-002I160 07NAD-P200100

Remover shaft, 17 mm Remover handle Attachment, 34 mm

07936-3710300 07936-3710100 07JAD-PL60100

TROUBLESHOOTING
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
• Worn balancer bearing
Hard to shift
• Bent shift fork
• Bent shift fork shaft
• Damaged shift drum guide groove
• Damaged shift fork guide pin
Transmission jumps out of gear
• Worn gear dogs or slots
• Worn shift drum guide groove
• Worn shift fork guide pin
• Worn shift fork groove in gear
• Worn shift fork shaft
• Bent fork shaft

11-5
CRANKSHAFT/TRANSMISSION
CRANKCASE SEPARATION
Refer to Service Information (page 11-3) for removal PLATE
of necessary parts before disassembling the crank- GUIDE
case.
Remove the tensioner guide plate bolts, plate and
tensioner guide.
Remove the cam chain.

CHAIN BOLTS
Remove the bolt and push plug plate.
BOLT PUSH PLUG PLATE

Remove the push plug and spring.

SPRING

PUSH PLUG
Remove the right crankcase bolt.
BOLT

11-6
 CRANKSHAFT/TRANSMISSION
Remove the three bolts and bearing retainer plates.
BOLTS/ BOLTS
Remove the left crankcase bolts. PLATES

Place the crankcase assembly with the right side

down. LEFT CRANKCASE

Do not ply the Carefully separate the left crankcase from the right
crankcase halves. crankcase while tapping them at several locations
with a soft hammer.

RIGHT CRANKCASE
Remove the dowel pins.
DOWEL PINS

TRANSMISSION
REMOVAL
Separate the crankcase halves (page 11-6).
SHIFT FORK SHAFTS
Pull the shift fork shafts and remove it from the shift
forks.

11-7
CRANKSHAFT/TRANSMISSION
Remove the shift forks and shift drum. SHIFT FORKS

SHIFT DRUM
Remove the mainshaft and countershaft together.
MAINSHAFT

COUNTERSHAFT
Disassemble the mainshaft and countershaft.
MAINSHAFT

COUNTERSHAFT

INSPECTION
GEARS
Check the gear dogs, dog holes and teeth for dam-
age or excessive wear.
Measure the I.D. of each gear.
SERVICE LIMIT:
M4, M5: 20.05 mm (0.789 in)
C1: 20.55 mm (0.809 in)
C2: 23.07 mm (0.908 in)
C3: 23.07 mm (0.908 in)

11-8
 CRANKSHAFT/TRANSMISSION
BUSHINGS
Check the bushings for wear or damage.
Measure O.D. of each bushing.
SERVICE LIMIT:
M4, M5: 19.91 mm (0.784 in)
C1: 20.41 mm (0.804 in)
C2, C3: 22.95 mm (0.904 in)
Calculate the gear-to-bushing clearance.
SERVICE LIMIT:
M4, M5, C1: 0.10 mm (0.004 in)
C2: 0.10 mm (0.004 in)
C3: 0.10 mm (0.004 in)
Measure I.D. of each bushing.

SERVICE LIMIT:
M4, C1: 17.04 mm (06.71 in)
C2, C3: 20.07 mm (0.790 in)

MAINSHAFT/COUNTERSHAFT
Check the spline grooves and sliding surfaces for
abnormal wear or damage. M4
Measure the O.D. of the mainshaft and countershaft
at the gear and bushing sliding areas.
SERVICE LIMIT:
Mainshaft (at M4 gear bushing):
16.93 mm (0.667 in)
Countershaft (at C1 gear bushing):
16.93 mm (0.667 in)
(at C2 gear bushing):
19.94 mm (0.785 in)
(at C3 gear bushing): C2 C3 C1
19.94 mm (0.785 in)
Calculate the bushing-to-shaft clearance.
SERVICE LIMIT:
M4, C1: 0.10 mm (0.004 in)
C2: 0.10 mm (0.004 in)
C3: 0.10 mm (0.004 in)

SHIFT DRUM
Inspect the shift drum end for scoring, scratches, or
SHIFT DRUM
evidence of sufficient lubrication.
Check the shift drum grooves for abnormal wear or
damage.

11-9
CRANKSHAFT/TRANSMISSION
SHIFT FORK
Check the shift forks for deformation or abnormal
wear.
Measure each shift fork claw thickness.
SERVICE LIMIT: 4.50 mm (0.177 in)
Measure I.D. of each fork.

SERVICE LIMIT: 10.05 mm (0.396 in)

SHIFT FORK SHAFT

Check the shift fork shafts for damage and straight-
ness.
Measure the shift fork shaft O.D.

SERVICE LIMIT: 9.93 mm (0.391 in)

BEARING REPLACEMENT
INSPECTION
Turn the inner race of each bearing with your finger.
The bearings should turn smoothly and quietly.
Also check that bearing outer races fit tightly in the
crankcases.

REMOVAL
Remove the bolts and mainshaft bearing setting MAINSHAFT
BOLTS/SETTING PLATES
plates from the right crankcase.
BEARING
Drive out the mainshaft bearing from the right
crankcase.
Drive out the countershaft bearing from the right
crankcase with following tools.

TOOLS:
Remover shaft, 17 mm 07936-3710300
Remover handle 07936-3710100
Remover weight 070MC-KPLI300
COUNTERSHAFT
BEARING

11-10
 CRANKSHAFT/TRANSMISSION
Remove the countershaft dust seal and gear shift COUNTERSHAFT
spindle dust seal from the left crankcase.
DUST SEAL

GEAR SHIFT
SPINDLE
DUST SEAL

Drive out the countershaft bearing from the left

COUNTERSHAFT
crankcase.
BEARING

Drive out the mainshaft bearing from the left crank- MAINSHAFT
case with following tools.
BEARING
TOOLS:
Remover head, 12 mm 070MC-KPLI410
Remover shaft, 12 mm 070MC-KPLI420
Remover weight 070MC-KPLI300

11-11
CRANKSHAFT/TRANSMISSION
INSTALLATION
Lubricate the all bearings with engine oil.
DRIVER
Drive new bearings into the left crankcase with fol- ATTACHMENT
lowing tools:
TOOLS:
RIGHT CRANKCASE
Mainshaft bearing:
Driver 070GD-001I100
Attachment, 37 x 40 mm 070GD-002I150
Pilot, 17 mm 070GD-004I150
Countershaft bearing:
Driver 070GD-001I100
Attachment, 42 x 47 mm 070GD-002I160
Pilot, 17 mm 070GD-004I150 BEARING PILOT

LEFT CRANKCASE
Mainshaft bearing:
Driver 070GD-001I100
Attachment, 32 x 35 mm 070GD-002I140
Pilot, 12 mm 070GD-004I130
Countershaft bearing:
Driver 070GD-001I100
Attachment, 42 x 47 mm 070GD-002I160
Pilot, 20 mm 070GD-004I160

Apply grease to the new dust seal lips.

Drive to case 0.5 – 1.0 mm (0.02 – 0.04 in)
Install the countershaft and gearshift spindle dust end face
seals with following tools as shown.

TOOLS:
Countershaft dust seal:
Driver 070GD-001I100
Attachment, 34 mm 07JAD-PL60100
Pilot, 20 mm 070GD-004I160
Gearshift spindle dust seal:
Driver 070GD-001I100 GEAR SHIFT
Attachment, 22 x 24 mm 07746-0010800 SPINDLE COUNTERSHAFT
Pilot, 14 mm 07746-0041200 DUST SEAL DUST SEAL

Apply locking agent to the threads of the setting

plate bolt. BOLTS/
Install the setting plates and bolts. SETTING PLATES
Tighten the bolts to the specified torque.

TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)

11-12
 CRANKSHAFT/TRANSMISSION
INSTALLATION
Clean all parts in solvent.
Apply clean engine oil to each gear teeth. CORRECT INCORRECT
Apply molybdenum oil solution to the bushing slid-
ing surface to ensure initial lubrication.
Assemble all parts into their original positions.
• Check the gears for freedom of movement or
rotation on the shaft.
• Install the washers and snap rings with the
chamfered side facing of the thrust load side.
Confirm the inner side of snap rings and washer
when you detect the chamfered side.
• Do not reuse worn snap ring which could easily
spin in the groove. SNAP RING
• Check that the snap rings are seated in the
grooves and align their end gaps with the
grooves of the spline.
MAINSHAFT

: Each gear teeth THRUST WASHER

SPLINE WASHER
: Bushing, spline washer and spline collar
SPLINE COLLAR
SNAP RING

SPLINE
WASHER

M4 BUSHING
M2 GEAR
(19T)

M5 GEAR
M4 GEAR (32T)
(22T) M3 GEAR
(23T)
Chamfered Side

MAINSHAFT/ M1 GEAR
(13T)

Sharped
Chamfered Edge Chamfered
Side Side Side

11-13
CRANKSHAFT/TRANSMISSION
COUNTERSHAFT

: Each gear teeth

: Bushing and spline washer

C3 GEAR
SPLINE WASHER (30T) THRUST
C3 BUSHING WASHER
C4 GEAR
C1 GEAR (24T)
(40T)
SNAP
THRUST RING
WASHERS
C1 BUSHING

THRUST
WASHER

THRUST
WASHER

C2 BUSHING
C2 GEAR
(34T)
THRUST
C5 GEAR
WASHER
(30T)

Chamfered Side
COUNTERSHAFT

Sharped Edge
Side

11-14
 CRANKSHAFT/TRANSMISSION
If the crankshaft removed, install the crankshaft first
(page 11-18).
Apply molybdenum oil solution to the shift fork
grooves.
Apply clean engine oil to the transmission gear
teeth.

Install the mainshaft and countershaft together into

MAINSHAFT
the left crankcase. Be sure to install the three end
washers (mainshaft; left only/countershaft; both
ends).

COUNTERSHAFT
Each shift fork has an identification marks; “R/L”
(right and left), “C” (center),. "C" MARK
Install the shift forks into the shifter gear grooves
with the marks facing up (left crankcase side).

"R/L" MARKS

Apply clean engine oil to the guide grooves in the SHIFT FORKS
shift drum and install it, while aligning the shift fork
guide pins with the guide grooves.

SHIFT DRUM

11-15
CRANKSHAFT/TRANSMISSION
Apply clean engine oil to the shift fork shaft and SHIFT FORKS SHAFT
insert it through the shift forks into the right crank-
case.
Rotate the mainshaft by hand to see if the gears
rotate freely.
Assemble the crankcase (page 11-19).

CRANKSHAFT
REMOVAL
Remove the transmission (page 11-7).
CRANKSHAFT
Remove the crankshaft from the right crankcase.

INSPECTION
CRANKSHAFT RUNOUT
Place the crankshaft on a stand or V-blocks.
Set the dial indicator on the shafts.
Rotate the crankshaft two revolutions and read the
runout.
SERVICE LIMIT: 0.03 mm (0.001 in)

47.5 mm (1.87 in) 43.0 mm (1.69 in)

11-16
 CRANKSHAFT/TRANSMISSION
BIG END SIDE CLEARANCE
Measure the side clearance of the connecting rod
big end with feeler gauge.
SERVICE LIMIT: 0.80 mm (0.032 in)

BIG END RADIAL CLEARANCE

Measure the radial clearance of the connecting rod
big end.
SERVICE LIMIT: 0.05 mm (0.002 in)

TIMING SPROCKET
If the timing Check the timing sprocket teeth for wear or damage.
sprocket teeth are
Remove the timing sprocket if necessary.
worn or damaged,
When installing the timing sprocket, while align the CRANK PIN
check the cam
center of the timing sprocket teeth with the center of
chain, tensioner
the crank pin.
and cam sprocket.

TIMING
SPROCKET
BEARING REPLACEMENT
INSPECTION
Turn the inner race of bearing with your finger.
The bearing should turn smoothly and quietly.
Also check that bearing outer races fit tightly in the
crankcase.

11-17
CRANKSHAFT/TRANSMISSION
REMOVAL
Drive out the crankshaft bearing from the right CRANKSHAFT
crankcase.
BEARING

INSTALLATION
If the crankshaft bearing inner race is removed,
install it as shown. IN SIDE

INNER RACE

Lubricate the all bearings with engine oil.

ATTACHMENT DRIVER
Drive new bearings into the right crankcase with fol-
lowing tools:

TOOLS:
Crankshaft bearing:
Driver 070GD-001I100
Attachment, 52 x 55 mm 07NAD-P200100
Pilot, 30 mm 07746-0040700

PILOT
INSTALLATION
Install the crankshaft into the right crankcase.
CRANKSHAFT
Install the transmission (page 11-13).

11-18
 CRANKSHAFT/TRANSMISSION

CRANKCASE ASSEMBLY
Clean the left and right crankcase mating surfaces
thoroughly, being careful not to damage them and
check for damage.
Apply a light but through coating of sealant to all
crankcase mating surface except the oil passage
area.

Install the dowel pins.

DOWEL PINS

Do not force the Install the left crankcase over the right crankcase.
LEFT CRANKCASE
crankcase halves
together, If there is
excessive force
required, some-
thing is wrong.
Remove the right
crankcase and
check for mis-
aligned parts.

RIGHT CRANKCASE
Install the left crankcase bolts, and tighten the bolts
BOLTS
in a crisscross pattern in 2-3 steps.

11-19
CRANKSHAFT/TRANSMISSION
When installing the Install the bearing retainer plates and bolts to the BOLTS/
retainer plate, pull- specified torque. PLATES
PLATES
ing the crankshaft
and hook the plate TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft) Hook
tab to the crank-
BOLTS
shaft bearing
groove.

CRANKSHAFT

Install and tighten the right crankcase bolt.

BOLT

Apply molybdenum oil solution to the push plug. SPRING

When installing the Install the push plug and spring.
push plug, make
sure the crankshaft
bearing outer
touches the taper
part of push plug. PUSH PLUG

BEARING PUSH PLUG

Apply locking agent to the threads of the push plug BOLT PUSH PLUG PLATE
bolt.
Install the push plug plate and bolt.
Tighten the bolt to the specified torque.

TORQUE: 10 N·m (1.0 kgf·m, 7 lbf·ft)

11-20
 CRANKSHAFT/TRANSMISSION
Install the cam chain through the crankcase. PLATE
Install the cam chain to the sprocket. GUIDE

Install the tensioner guide and tensioner guide

plate.
Install and tighten the tensioner guide plate bolts.
Install the removed parts in the reverse order of
removal (page 11-3).

CHAIN BOLTS

11-21
CRANKSHAFT/TRANSMISSION

11-22