Service Information 9-1 Transmission DisassemblyIAssembly 9-8
Troubleshooting 9-1
Crankshaft.Connecting Rod Removal 9-10
Countershaft Bearing Cover 9-2 Alternator Shaft
DisassemblylAssembly9-12
Removalllnstallation 9-3 Crankshaft Bearing Replacement 9-14
Crankcase Separation 9-4 Crankshaft, Connecting Rod
Installationg-16
Transmission Removalllnstallation 9-6 Crankcase Installation 9-1
8
Service lnformation
This section covers crankcase separation in order to service the crankshaft, transmission and alternator shaft.
The following parts must be removed before separating the crankcase.
-Alternator (Section 13)
-Clutchlgearshift linkage (Section
8)
-Cylinder headlcylinderlpiston (Section
7)
-Engine (Section
6)
I
-Oil pump (Section
4)
-Starter motor (Section 15)
Prior to assembling the crankcase halves. apply a sealant to their mating surfaces. Wipe off excess sealant thoroughly.
Mark and store the bearing inserts to be sure of their correct locations for reassembly. If the inserts are improperly
installed they will block the oil holes, causing insufficient lubrication and eventual engine seizure.
Troubleshooting
Excessive Noise
Worn connecting rod big-end bearing
-
Bent connecting rod
-
Worn crankshaft main bearing
Worn transmission bearing
Hard To Shift
Improper clutch operation
.
Incorrect engine oil viscosity
Incorrect clutch adjustmest
Bent shift fork
Bent fork shaft
Bent fork claw
Damaged shift drum cam grooves
Bent shift spindle
Transmission Jumps
Out
Of
Gear
Worn gear dogs or slots
Bent fork shaft
Broken shift drum stopper
Worn or bent shift forks
Broken shift linkage return spring
Engine Vibration
Excessive crankshaft
runout
Loose engine mount bolts
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