DAELIM DAYSTAR -, Service Manual

Page: 106 / 214

10-1
Crank Case / Transmission / Crankshaft / Kick Starter
Service Information
General
●
To service the transmission, crank shaft and kick starter, the crank case must be separated.
- Clutch, gear shift linkage (
⇨
section 6)
- A.C. generator, starter clutch (
⇨
section 7)
- Cylinder head (
⇨
section 8)
- Cylinder, piston (
⇨
section 9)
- Starter motor (
⇨
section 18)
10. Crank Case/Transmission/Crankshaft/Kick Starter
Service Information
………………
10-1
Troubleshooting
……………………
10-2
Crank Case Disassembly
…………
10-3
Transmission Disassembly
………
10-4
Crankshaft Disassembly
…………
10-6
Crank Case Bearing
………………
10-7
Crankshaft Installation
……………
10-8
Transmission Assembly
…………
10-9
Kick Starter
…………………………
10-10
Crank Case Assembly
……………
10-12
Item Standard Service Limit
Shift fork/ Fork
I.D. 12.000-12.018(0.4724-0.4731) 12.05(0.474)
Shaft
Pole thickness 4.93-5.00(0.194-0.197) 4.5(0.18)
Shaft O.D. 11.976-11.994(0.4715-0.4722) 11.96(0.471)
Main shaft O.D. M3, M5 19.959--19.980(0.7858-0.7866) 19.930(0.7846)
C1 16.466-16.484(0.6483-0.6490) 16.440(0.6472)
Counter Shaft O.D. C2 19.974-19.987(0.7864-0.7869) 19.940(0.7850)
C4 19.959-19.980(0.7858-0.7866) 19.930(0.7846)
M5
Gear I.D.
M3, C2 23.020-23.041(0.9063-0.9071) 23.070(0.9083)
C4 20.020-20.041(0.7882-0.7890) 20.070(0.7902)
C1 20.000-20.021(0.7874-0.7882) 20.050(0.7894)
M5
Transmission Gear bushing O.D. M3, C2 22.979-23.000(0.9047-0.9055) 22.950(0.9035)
C1 19.959-19.980(0.7858-0.7866) 19.930(0.7846)
Gear-to-bushing I.D.
M3, C2 20.000-20.021(0.7874-0.7882) 20.050(0.7894)
C1 16.500-16.518(0.6496-0.6503) 16.550(0.6516)
Gear-to-bushing
M3, M5
0.020-0.062(0.0008-0.0024) 0.100(0.004)
clearance
C1, C2
Gear to-shaft
C4 0.040-0.082(0.0016-0.0032) 0.120(0.005)
clearance
Unit: mm(in)
Specifications
10