(CRANKSHAFT/BALANCER 10-010. CRANKSHAFT/BALANCER SERVICE INFORMATION 10-1 CRANKCASE BEARING ‘TROUBLESHOOTING 10-2 REPLACEMENT 10-6 GRANKSHAFT/BALANCER CRANKCASE SEPARATION 108 OA AON 10-10 BALANCER/CRANKSHAFT ROAR 10-4 CRANKCASE ASSEMBLY 10-11 ) SERVICE INFORMATION GENERAL Engine ‘Section 5 Ot! pamp Secton 2 Cylinder head Section 6 Cylinder/aiston Section 7 Clutch Section & Altemeter Section 9 SPECIFICATIONS rid rem STANDARD SERVICE LiMiT. Connecting rod big end side clearance (0.050—0.60 mm (0.0020-0.0256 in) 0.80 mm (0.081 in) Connecting red big end radial clearance 0.006 0.018 mm (0.0002-0.0007 in) | 0.05 mm (0.002 in) Crancshaft runout — [0.10 mm (0.004 in) TORQUE VALUE Cronkesse tot 12am 142 kgm, 8) roois Special Universal bearing cule 7821 ~9010000 Boring ie catch Oroat neo" 09 , Snoring remover 07930—MRSoIoo %eaivalent commercial femover ange 07936—Ke10100 Remover sng weight 07741 ~9010201 Need rece remover oree—-NiKse 100 Dawn remover shat o7748 a¢60%00 Palo son 07991-Meao0000r97891 -ME4G00A fssortly colar 7991 Kr00100 Ted adaptor 07931 400200 Attachment, 78 x 90 mm d7eab—s040101 Common Brver 0749-0010000 Pio. 96 mm o7r46 a0r0e00 ‘tachment 62 x 66 mn 97740-06t0s00 Pie, 28 mh 07748 -080600 btchmant, 42x 47 mm 07748 -o010300 Plot, 40 rm 07746 -oo40800 ‘tachment, 2 x 36 mm 87746 oot0v00 Attachrnen, 62 © 38 rn 877400010800 Astachinon, 36 mo 1.0. O76 —on0400 Attachment, 72x 75mm 077460010600 Plot. 20-0 77480040800 10-1 ——CRANKSHAFT/BALANCER TROUBLESHOOTING Excessive Noise rankaheft = Worn connecting rod bearings — Bent connecting rod — Worn crankshaft bearings nprope installation — Worn balancer beatings 10-2CRANKSHAFT/BALANCER CRANKCASE SEPARATION FERS ITA Ramave the following: bolt, collar and cam chain tensioner = carn chain = cam chain drive sprocket Inspect the cam chain tensioner for excessive wear or dam- 208 Loosen and remove the right crankease belts Loosen and remove the left crankease bolts in g crisscross pat- tein in two or more steps. 10-3CRANKSHAFT/BALANGER Remove the right crankcase from the left crankcase, (1) GasKeT NOTE * Separate the right and left crankcases from each othe: while tapping them at saveral locations with a soft hammer CAUTION ‘Do not pry the crankeases apart with a screwdriver. Remove the gasket and dowel pins. BALANCER/CRANKSHAFT REMOVAL |1) BALANCER Remove the transmission (nage 17-2). Insert a proper sized nail into the holes in the balancer, while prying the scissors gears with a screwdriver. Turn the balancer weight with the balancer weight out of she crank weight, and paint on the balancer drive gear end driven gear, Romove the balancer and pull out the nail. Using @ hydraulic press, press the crankshaft out of the left 11) CRANKSHAFT ‘cronkense, Remove the left crankshaft beating wth a bearing puller 1 ‘comes out with the crankshaft TooL: Universel bearing puler 07631—0010000 or equivalent commoretatly available in U.S.A. Bearing puller catch 07931—MK20100 valent commercially |3} PILOT 20. mm or EQUIVALENT Discard the bearing. CAUTION + Always replace the left bearing with a new one if t comes with the crankshaft. 10-4CRANKSHAFT/BALANCER CRANKSHAFT INSPECTION Sot the crankshaft on a ttuing stand or V blocks and measurs the runout using a dil indicator. SERVICE LIMIT: 0.10 mm (0.004 in} emm (0.24 in} Measure the side clearance of the connecting rod big end with 2 feoler gauge SERVICE LIMIT: 0.80 mm (0.031 In} ‘Measure the connecting rod big ond radicl cloarance. SERVICE LIMIT: 0.05 mm (0.002 in) BALANCER DISASSEMBLY/ASSEMBLY (1) WASHER ji Separate the outer driven gear from the inner driven gear by re- moving the snap ring and cone spring washer. Remove the four springs from the inner driven gear (3) SNAP RING 10-5CRANKSHAFT/BALANCER Check the gears and springs for weer, damage or fatigue, and (1) SPRINGS (2) OUTER DRIVEN GEAR replace If necessary. sii Ingtall the four epringe into the inner driven goar. Install the outer driven gear onto the inner driven gear NOTE + Position the punch mark on the outer gear hetwaen the punch marks on the inner got Install the cone spring washer and the snap ring soouroly, CRANKCASE BEARING REPLACEMENT INSPECTION Turn the inner reces with your finger. ‘The beerings should turn smoothly and quietiy. Algo check thst the outor raves of tha baaringe fit tightly in the crankcase, Replace the bearings if necessary. RIGHT CRANKCASE BEARING REPLACEMENT Romove the right balancer bearing using the following tools. TooLs: Bearing remover 07936—MK50100 oF oquivalont commorcilly available in U.S.A. Remover handle 07936—KC10100 or equivalent commercially available in U.S.A. 077410010207 oF equivalent commoretally available in U.S.A,CRANKSHAFT/BALANCER Bend down the tabs of the lock plete, and remove the bolt, lock plate and beating stopper plate Discard the lock plate. Romeve each boating cut of the right erankea Remove the oil seal and ciscard it after removing the éght crankshaft bearing, Apoly clean engine oil 10 the ip of the new right counter shaft cil seal and install it securely 2) ATTACH. Apply ell to each new bearings, and drive each bearing into the few fight crankease, NOTE Drive in the bearing perpendiculerly to the right crankoasa. Too.s: Crankshaft beating Driver 077490010000 Attachment, 72 x75mm 077460010600 Pilot, 35 mm. 07746-0040800 {ht mainshaft bearing Driver 077490010000 Attechment, 52x 55mm 077460010400 ‘ Pilot, 25 mm 077460040600 (1) BALANCER (2) MAINSHAFT. BEARING: BEARING Right countershaft bearing Driver 077490010000 Attachment, 42 x47 mm 07746—9010300 Puiot, 20 mm 077460040500 Right balancer bearing Driver 077490010000 Attachment, 42x47 mm 077460010300 (4) CRANKSHAFT! BEARING,CRANKSHAFT/BALANCER Install the bearing stopper plats and new lock plate, and secure them with a bolt. Berd up the tabs of the lock plate against the bolt LEFT CRANKCASE BEARING REPLACEMENT (1) REMOVER HANDLE’, os. (2) BEARING : ley iy REMOVER Romove the left belancer bearing using the following tools. TooLs: Bearing remover 07936—MK60100 or equivalent commarcially available in U.E.A. Remover handle 07936—Kc10100 wuivelent commarotally available in U.S.A. Remover sliding weight 07741—0010201 oF equivalent commercially available in U.S.A. Romove the needle bearing and check it for wear of damage, and replace if necessary. Remove the bolt and bearing race stopper. Remove the needle beating race from the right crankcase using the following touls. Toots: Needla raca remover 07GMe—MK50100 Booring remover shatt 077460060100 co atiaweeme ||) remover shar 10-8CRANKSHAFT/BALANCER Remove the le't countershaft bearing cil seal and discard it, i) COUNTERSHAFT Ol Be Check the gearshift spinde oil seal for wear, damage or fatigue, and replace it if necessary. Romove each bearing cut of the left crankoase. Replace the bearing plate if necessary. Apply oil to each new beering, and drive each bearing into the (1) DRIVER left crankease (2) ATTACH Nore + Drive in the bi rings perpendicularly to the left crankcase. Toots: Loft crankshaft beering Driver 07743—0010000 Attachment, 78x90 mm 07GAD—SD40101 Pilot, 40 mm 07746—0040900 Loft mainshaft bearing race Driver 07749-0010000 Attachment, 32x35 mm 07746—0010100 wo (0) COUNTERSHAET © “2) CRANKSHAFT BEARING, 3 BEARING Left countershaft booting Driver 07749-0010000 ttachment, 62x 68mm — 07746—0010500 lot, 25 mm 07746040800 Loft balancer bearing Driver 07748—0010000 Attachment, 42x47 mm 07746—0010300 10-9CRANKSHAFT/BALANCER Install a new countershaft cil seal in the left erankease, anc apply oil to the oll seal lp, Secure the bearing race stopper plate with the bolt Install the nescle bearing into the bearing race. CRANKSHAFT/BALANCER INSTALLATION Clean the crankcase mating surfacas hafora assembling and check for wear or damage. NOTE + IF thete ® minor roughness oF imegularities on the crankcase mating surfeces, dress them with an cil stone. + After cleaning, lubricate the crankshaft bearings and other contacting surfaces Install the special too! into the thread end of the crankshatt Positien tho orankehatt into the loft crankea Draw the crankshaft into the lett crankcase with the Following tools: NOTE + Draw in the crankshaft, making sure the connecting rad is not comprossed against the crankcase edge. TooLs: Puller shaft 97931—Me40000 Assembly collar 07931—KF00100 Thread adaptor 07931—KF00200 Attachment |.D. 35 mm 077460030400 Insert a proper sized nail into the hole in the balencer, while prying the scissors gears with a screw driver Install the balancer with the paint marks aligned, 10-10CRANKSHAFT/BALANCER ‘Turn the barencer, and meke sure the puntch marks on the ba (1) PUNCH MARKS ancer drive geer and driven gear are aligned. Draw the nail out of the balancer. Inetall the transmissicn (ssction 11}, CRANKCASE ASSEMBLY UIP SASKET Install the three dowel pins and a naw gesket Assemble the right and left crankcases being careful to align the dowel pins and snatts, CAUTION + Don't force the crankease halves together; if there is excessive force required, something is wrong, Remove the right crank ease and check for msatigned parts. Tighten the left crankcase bolts in a crisscross pattern in two or more steps. TORQUE: 12 Nem (1.2 kgm, 9 feb) Tighten the right crankcase bolts. TORQUE: 12.Nem (1.2 kgm, 8 tb)CRANKSHAFT/BALANCER Apply a locking egent to the threads of the tensioner bolt. ‘Secure che cam chain tensioner with the collar and bolt. Install the cam chein drive sprocket and cam chain, NOTE +The cam chain drive earackat will only go on ane position becauas of oxtr signing spline. Reinetall the romoved parte in the reverae order of removal (page 10-1), 10-12