
CRANKCASE/TRANSMISSION
11-3
SERVICE INFORMATION
GENERAL
• The crankcase must be separated to service the following:
– Transmission
– Crankshaft (page 12-5)
– Piston/connecting rod/cylinder (page 12-14)
• The following components must be removed before separating the crankcase:
– Engine (page 7-4)
– Clutch (page 9-6)
– Gearshift linkage (page 9-22)
– Starter clutch (page 9-17)
– Flywheel (page 10-6)
– Cylinder head (page 8-12)
– Oil pan (page 4-6)
– Oil pump (page 4-8)
– Starter motor (page 19-6)
– Water pump (page 6-18)
– EOP switch (page 4-5)
– VS sensor (page 20-24)
– Neutral switch (page 20-35)
• Be careful not to damage the crankcase mating surfaces when servicing.
• Prior to assembling the crankcase halves, apply sealant to their mating surfaces. Wipe off excess sealant thoroughly.
SPECIFICATIONS
Unit: mm (in)
TORQUE VALUES
ITEM
STANDARD
SERVICE LIMIT
Shift fork
I.D.
12.000 – 12.018 (0.4724 – 0.4731)
12.03 (0.474)
Claw thickness
5.93 – 6.00 (0.233 – 0.236)
5.9 (0.23)
Shift fork shaft O.D.
11.957 – 11.968 (0.4707 – 0.4712)
11.95 (0.470)
Transmission
Gear I.D.
M5, M6
28.000 – 28.021 (1.1024 – 1.1032)
28.04 (1.104)
C1
24.000 – 24.021 (0.9449 – 0.9457)
26.04 (1.025)
C2, C3, C4
31.000 – 31.025 (1.2205 – 1.2215)
31.04 (1.222)
Gear busing O.D.
M5, M6
27.959 – 27.980 (1.1007 – 1.1016)
27.94 (1.100)
C2
30.955 – 30.980 (1.2187 – 1.2197)
30.94 (1.218)
C3, C4
30.950 – 30.975 (1.2185 – 1.2195)
30.93 (1.218)
Gear-to-bushing
clearance
M5, M6
0.020 – 0.062 (0.0008 – 0.0024)
0.10 (0.004)
C2
0.020 – 0.070 (0.0008 – 0.0028)
0.10 (0.004)
C3, C4
0.025 – 0.075 (0.0010 – 0.0030)
0.11 (0.004)
Gear bushing I.D.
M5
24.985 – 25.006 (0.9837 – 0.9845)
25.016 (0.9849)
C2
27.985 – 28.006 (1.1018 – 1.1026)
28.021 (1.1032)
Mainshaft O.D.
at M5
24.967 – 24.980 (0.9830 – 0.9835)
24.96 (0.983)
Countershaft O.D.
at C2
27.967 – 27.980 (1.1011 – 1.1016)
27.96 (1.101)
Bushing to shaft
clearance
M5
0.005 – 0.039 (0.0002 – 0.0015)
0.06 (0.002)
C2
0.005 – 0.039 (0.0002 – 0.0015)
0.06 (0.002)
Mainshaft bearing set plate bolt
12 N·m (1.2 kgf·m, 9 lbf·ft)
Apply a locking agent to
the threads.
Shift drum bearing set bolt
12 N·m (1.2 kgf·m, 9 lbf·ft)
Apply a locking agent to
the threads.
Crankcase
6 mm bolt
12 N·m (1.2 kgf·m, 9 lbf·ft)
8 mm bolt
24 N·m (2.4 kgf·m, 18 lbf·ft)
8 mm bolt (main journal bolt)
15 N·m (1.5 kgf·m, 11 lbf·ft) + 120
°
See page 11-17
Replace with a new one.
10 mm bolt
39 N·m (4.0 kgf·m, 29 lbf·ft)
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys.
email: [email protected]
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