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13. CRANKCASE/TRANSMISSION

SERVICE INFORMATION······················ 13-2 CRANKCASE······································ 13-5

TROUBLESHOOTING ·························· 13-3 TRANSMISSION·································· 13-8

COMPONENT LOCATION ····················· 13-4

13

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CRANKCASE/TRANSMISSION
SERVICE INFORMATION
CRANKCASE/TRANSMISSION

GENERAL
• The crankcase must be separated to service the following:
– transmission
– crankshaft (page 14-4)
– balancer (page 14-17)
– piston/connecting rod/cylinder (page 14-13)
• The following components must be removed before separating the crankcase:
– engine (page 15-4)
– gearshift linkage (page 11-15)
– flywheel (page 12-5)
– cylinder head (page 10-15)
– cam chain tensioner lifter (page 10-22)
– cam chain/timing sprocket (page 10-23)
– oil strainer (page 9-8)
– pressure relief valve (page 9-7)
– engine oil filter (page 3-11)
– water pump (page 8-10)
– water hose joint (page 8-11)
– EOP switch (page 21-12)
– VS sensor (page 4-35)
– neutral switch (page 21-16)
• Be careful not to damage the crankcase mating surfaces when servicing.
• Clean the oil passages before assembling the crankcase halves.
• Prior to assembling the crankcase halves, apply sealant to their mating surfaces. Wipe off excess sealant thoroughly.
• The crankpin and main journal bearing inserts are select fit and are identified by color codes. Select replacement bearings from
the code tables. After selecting new bearings, recheck the oil clearance with a plastigauge. Incorrect oil clearance can cause
major engine damage.

TOOLS
Driver Attachment, 32 x 35 mm
07949-3710001 07746-0010100

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CRANKCASE/TRANSMISSION
TROUBLESHOOTING
Hard to shift
• Improper clutch operation
• Improper engine oil viscosity
• Bent shift fork
• Bent shift fork shaft
• Bent shift fork claw
• Damaged shift drum guide groove
• Bent gearshift spindle (page 11-17)
Transmission jumps out of gear
• Worn gear dogs
• Worn gear shifter groove
• Bent shift fork shaft
• Broken shift drum stopper arm (page 11-17)
• Broken shift drum stopper arm return spring (page 11-17)
• Worn or bent shift forks
• Broken gearshift spindle return spring (page 11-17)
Excessive engine noise
• Worn or damaged transmission gear
• Worn or damaged transmission bearings

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CRANKCASE/TRANSMISSION
COMPONENT LOCATION
12 N·m (1.2 kgf·m, 9 lbf·ft)

15 N·m (1.5 kgf·m, 11 lbf·ft) + 120°

24 N·m (2.4 kgf·m, 18 lbf·ft)

39 N·m (4.0 kgf·m, 29 lbf·ft)

24 N·m (2.4 kgf·m, 18 lbf·ft)

12 N·m (1.2 kgf·m, 9 lbf·ft)

12 N·m (1.2 kgf·m,

9 lbf·ft)

12 N·m (1.2 kgf·m,

9 lbf·ft)

12 N·m (1.2 kgf·m,

9 lbf·ft)

12 N·m (1.2 kgf·m, 9 lbf·ft)

12 N·m (1.2 kgf·m, 9 lbf·ft)

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CRANKCASE/TRANSMISSION
CRANKCASE
SEPARATION
Refer to Service Information for removal of necessary
[1]/[2]
parts before separating the crankcase (page 13-2).
Remove the crankcase 6 mm bolts [1] and sealing
washer [2].

[1]

Place the engine upside down.

[1]
Loosen the crankcase 6 mm bolt [1], 8 x 75 mm bolts
[2], 8 x 55 mm bolt [3] and 10 mm bolts [4] in a
crisscross pattern in 2 or 3 steps, and remove all the
bolts and sealing washer [5].

[2]/[5]

[2]
[3]

[1] [4]

Loosen the crankcase main journal bolt [1] in a

[1]
crisscross pattern in 2 or 3 steps, and remove them.
Do not pry the Separate the lower crankcase [2] from the upper
crankcase halves crankcase.
with a screwdriver.

[2]

Remove the dowel pins [1] and oil orifices [2].

[1]

[2] [1]

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CRANKCASE/TRANSMISSION
ASSEMBLY
Clean the upper and lower crankcase mating surfaces
thoroughly, being careful not to damage them.
Check the crankcase oil passages for clogs, and clean
them if necessary.
Apply liquid sealant to the crankcase mating surface as
shown (page 1-18).

• Do not apply liquid sealant more than necessary.

• Do not apply liquid sealant to the crankcase main
journal bolts area and the oil passage area.

Clean the oil orifices in solvent thoroughly.

[2]
Check the oil orifices for clogs, and replace them if
necessary.
Install the oil orifices Install the oil orifices [1] into the upper crankcase [2]. Upper
with its large I.D. crankcase
side facing the side
upper crankcase.

[1]

Install the dowel pins [1] into the upper crankcase [2].
[1]

[2] [1]

Apply molybdenum oil solution to the main journal

[1]
bearing [1] sliding surfaces on the lower crankcase.

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CRANKCASE/TRANSMISSION
Install the lower crankcase [1] onto the upper
[2]
crankcase.
Install new crankcase main journal bolts [2]. 4 2 6

• Tighten the crankcase main journal bolts using the

Plastic Region Tightening Method.
• Do not reuse the crankcase main journal bolts, 3 1 5
because the correct axial tension will not be
obtained.
• The crankcase main journal bolts are pre-coated
with an oil additive for axial tension stability. Do not
remove the oil additive from the new crankcase main
journal bolt surfaces.
[1]
Make sure the upper and lower crankcase are seated
securely.
Tighten the crankcase main journal bolts in numerical
order as shown in a crisscross pattern in 2 or 3 steps to
the specified torque.
Further tighten the crankcase main journal bolts 120°.
TORQUE: 15 N·m (1.5 kgf·m, 11 lbf·ft) + 120°
Install a new sealing washer [1] and crankcase bolts.
[5]
Tighten the crankcase bolts in a crisscross pattern in 2
or 3 steps to the specified torque.

• The sealing washer location is indicated on the

lower crankcase by the " " mark.
[1]/[3]
TORQUE:
Crankcase 10 mm bolt [2]:
[3]
39 N·m (4.0 kgf·m, 29 lbf·ft)
[4]
Crankcase 8 x 75 mm bolt [3]:
24 N·m (2.4 kgf·m, 18 lbf·ft)
Crankcase 8 x 55 mm bolt [4]: [5] [2]
24 N·m (2.4 kgf·m, 18 lbf·ft)
Crankcase 6 mm bolt [5]
12 N·m (1.2 kgf·m, 9 lbf·ft)
Place the engine with the lower side down.
[1]/[2]
Install a new sealing washer [1] and crankcase 6 mm
bolts [2].

• The sealing washer location is indicated on the

upper crankcase by the " " mark.
[2]
Tighten the crankcase 6 mm bolts to the specified
torque.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)
Install the removed parts in the reverse order of
removal (page 13-2).

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CRANKCASE/TRANSMISSION
TRANSMISSION
REMOVAL/DISASSEMBLY
Separate the crankcase halves (page 13-5).
[1]
Align the index line [1] on the balancer drive gear with
the upper crankcase top surface of the front side.

Front

Remove the countershaft assembly [1] and dowel pin

[1]
[2].

[2]

Remove the shift drum bearing setting washer-bolts [1].

[1]

Remove the shift fork shaft [1] and shift forks [2].

[1] [2]

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CRANKCASE/TRANSMISSION
Remove the shift drum [1]/bearing [2] assembly.
[1]
Remove the shift drum bearing from the shift drum.

[2]

Remove the bolts [1] and balancer/right mainshaft

[2]
bearing setting plate [2].

[1]

Slide the mainshaft assembly off the upper crankcase

and remove the right mainshaft bearing [1].

[1]

Remove the mainshaft assembly [1].

[1]

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CRANKCASE/TRANSMISSION
Disassemble the mainshaft assembly [1] and
[1]
countershaft assembly [2].

• Keep track of the disassembled parts (gears,

bushings, washers, and snap rings) by sliding them
onto a tool or a piece of wire.
• Do not expand the snap ring more than necessary
for removal. To remove a snap ring, expand the
snap ring and pull it off using the gear behind it.

[2]

INSPECTION
Inspect the following parts for scratch, damage,
abnormal wear and deformation. Replace if necessary.
– transmission gears
– transmission bushings
– transmission bearings
– shift drum/bearing
– shift forks
– shift fork shaft
Measure each part and calculate the clearance
according to CRANKCASE/TRANSMISSION
SPECIFICATIONS (page 1-9).
Replace any part if it is out of service limit.

LEFT MAINSHAFT BEARING OUTER

RACE REPLACEMENT
Remove the following:
[2]
– balancer (page 14-17)
– piston (page 14-13)
Remove the bolt [1] and bearing outer race setting plate
[2].
Remove the left mainshaft bearing outer race [3] from
the upper crankcase using a suitable tool.

[3] [1]

Drive in a new left mainshaft bearing outer race [1]

[2]
squarely into the upper crankcase until it is fully seated
using the special tools.
TOOLS:
[2] Driver 07949-3710001
[3] Attachment, 32 x 35 mm 07746-0010100

[1] [3]

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CRANKCASE/TRANSMISSION
Apply locking agent to the bearing outer race setting
[1]
plate bolt threads (page 1-18).
Install the bearing outer race setting plate [1], bolt [2]
and tighten the bolt to the specified torque.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)
Install the removed parts in the reverse order of
removal.

[2]

ASSEMBLY
Clean all parts in solvent, and dry them thoroughly.
Apply engine oil to the gear teeth, rotating surface and CORRECT INCORRECT
bearing.
Apply molybdenum oil solution to the gear spline
bushing outer surface (M6, C3, C4), gear bushing entire
surface (M5, C2), needle bearing rotating area (C1) and
gear shifter grooves (M3/4, C5, C6).
Assemble the mainshaft and countershaft.

• Coat each gear with clean engine oil and check for
smooth movement.
• Align the lock washer tabs with the spline washer
[1]
grooves.
• Always install the thrust washers and snap rings with
the chamfered (rolled) edge facing away from the
thrust load.
• Install the snap rings [1] so that the end gap aligns
with the groove of the splines.
• Make sure that the snap rings are fully seated in the
shaft groove after installing them.

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CRANKCASE/TRANSMISSION
MAINSHAFT

MAINSHAFT/M1 GEAR (14T)

: Gear teeth, rotating surface and bearing

M5 GEAR BUSHING : Gear spline bushing outer surface, gear

bushing entire surface and gear shifter grooves

M5 GEAR (20T)

M3/4 GEAR (20/20T)

M6 GEAR SPLINE BUSHING

THRUST WASHER
M6 GEAR (23T)

SPLINE WASHER
M2 GEAR (19T)
SNAP RING

SNAP RING NEEDLE BEARING

SPLINE WASHER

SPLINE WASHER

LOCK WASHER

THRUST WASHER

COUNTERSHAFT

: Gear teeth, rotating surface and bearings

: Gear spline bushing outer surface, gear

C5 GEAR (23T) bushing entire surface, needle bearing
rotating area (C1) and gear shifter grooves
SNAP RING
SPLINE WASHER
NEEDLE BEARING C3 GEAR SPLINE BUSHING
C3 GEAR (32T)
THRUST WASHER
LOCK WASHER
NEEDLE BEARING
SPLINE WASHER
C1 GEAR (46T)
C4 GEAR SPLINE BUSHING
THRUST WASHER C4 GEAR (26T)
SPLINE WASHER

C6 GEAR (24T)
SNAP RING

SPLINE WASHER SNAP RING

C2 GEAR BUSHING
C2 GEAR (40T)

COUNTERSHAFT

BEARING SETTING RING

OIL SEAL

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CRANKCASE/TRANSMISSION
INSTALLATION
Align the index line [1] on the balancer drive gear with
[1]
the upper crankcase top surface of the front side.

Front

Install the mainshaft assembly [1] into the upper

crankcase.

[1]

Apply engine oil to the right mainshaft bearing.

Install the bearing Install the right mainshaft bearing [1] into the upper
into the crankcase crankcase.
with the marked
side facing out.

[1]

Apply locking agent to the balancer/right mainshaft

[1]
bearing setting plate bolts threads (page 1-18).
Install the balancer/right mainshaft bearing setting plate
[1] and setting plate bolts [2].
Tighten the setting plate bolts to the specified torque.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)

[2]

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CRANKCASE/TRANSMISSION
Apply engine oil to the shift drum bearing and shift drum
[2]
journal outer surface.
Install the bearing Install the shift drum bearing [1] onto the shift drum [2].
onto the shift drum
Install the shift drum/bearing assembly into the upper
with the marked
crankcase.
side facing out.

[1]

The shift forks have the following identification marks:

– "L" mark [1]: left shift fork
– "C" mark [2]: center shift fork
– "R" mark [3]: right shift fork
Apply molybdenum oil solution to the shift fork guide
area and guide pin.

[1] [2] [3]

Apply molybdenum oil solution to the shift fork shaft

outer surface.
Install the shift forks [1] into the shift drum guide
grooves and shifter groove (center shift fork) with the
identification marks facing toward the right side of the
engine, then insert the fork shaft [2].

[2] [1]

Apply locking agent to the shift drum bearing setting

[1]
washer-bolt threads (page 1-18).
Install and tighten the shift drum bearing setting
washer-bolts [1] to the specified torque.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)

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CRANKCASE/TRANSMISSION
Install the dowel pin [1] onto the upper crankcase hole.
[2]
Install the countershaft assembly [2] by aligning the
bearing setting ring and oil seal flange with the upper
crankcase grooves, and needle bearing cap hole with Align
the dowel pin.

• Make sure the index lines [3] on the bearing cap is

aligned with the upper crankcase top surface. Align
Assemble the crankcase halves (page 13-6).

[1]

[3]

Align
Align

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MEMO