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: info@motomatrix.co.uk
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