Service Information

GENERAL

• The crankcase must be separated to service the following:

- Transmission

- Crankshaft {Section 12)

- Piston/connecting rod (Section 12)

• The following components must be removed before separating the crankcase:

- Alternator/flywheel (Section 10)

- Clutch/gearshift linkage (Section 9)

- Cylinder head (Section 8)

- Engine (Section 7)

- Oil pan, oil pump and oil cooler (Section 4)

- Starter motor (Section 18)

- Water pump (Section 6)

• Be careful not to damage the crankcase mating surfaces when servicing.

• Prior to assembling the crankcasc halves, apply sealant to their mating surfaces. Wipe off any excess sealant thoroughly.

SPECIFICATIONS

Unit: mm (in)

ITEM

STANDARD

SERVICE LIMIT

Shift fork,

I.D.

12.000 12.021 (0.4724 - 0.4733)

12.03 (0.474)

fork shaft

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)

C2, C3, C4

31.000-31.025 (1.2205- 1.2215)

31.04 (1.222)

Gear bushing

M5, M6

27.959 - 27.980 (1.1007 - 1.1016)

27.94 (1.100)

O.D.

C2

30.955-30.980 (1.2187 - 1.2197)

30.94 (1.218)

C3, C4

30.950-30.975 (1.2185- 1.21951

30.93 (1.218)

Gear-to-bushing

M5, MB

0.020 - 0.062 (0.0008 - 0.0024)

0.10 (0.004)

clearance

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 10.983)

Countershaft O.D.

at C2

27.967 - 27.980 (1.1011 - 1.1016)

27.96 (1.101)

Bushing-to-shaft

M5

0.005 - 0.039 (0.0002 0.0015)

0.06 (0.002)

clearance

C2

0.005 - 0.039 (0.0002 0.0015)

0.06 (0.002)

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