L nsttill  tho com choln tensioner t pl:.ties..

Instal I the following parts: Sterter motor Cyllners/plstons Cylinder hea<H Gearshift linkage

Weter pump/water pipes Clutch

Staner clutchf1lternetor

 

(Section 20)

(Section 11)

(Section 10)

(Section 9)

(Section 6)

(Section 7)

(Section 8)

 

 

 

 

'fr 30-34  N·m

fj (3.0-3.4 k9'm. 22-25 ft lb)

 

 

C R AN KS HAFT / CONNEC T I NG  ROD

CRANKSHAFT REMOVAL

Separate the cra nkcase (page 12-2) and remove ma

dowel pins.

Remove the crankshaft.

 

(21DOWEL PINS

 

CONNECTING ROD REMOVA L

 

Check the con necting rod side clearance. SERVICE LIMIT: 0.40 mm (0.016 in)

 

 

Remove the connecting rod bearing caps and note their locations.

 

NOTE

 

Tap the side of the cap lightly if it is hard to

rem O¥e.

(1) BEARI NG CAP NU"[S

 

 

Mark the rods, bearings and caps as you remove them to indicate the correct cylinder and posi tion on the crankpins for reauembly.

 

Measure the conneC1ing rod small end 1.0.

SERVICE LIMIT:18.09 mm (0.712 in)                             

CRANKSHAFT INSPECTION

Place the crankshaft on a stand or Vee blocks.

Set a dial indicator on the main journals . Rotate the crankshaft two revolutions and read the runout.

 

The actual runout is 112 of the total indicator reading.

 

SERVICE LIMIT:0.05 mm (0.002 in)

 

BEARING  INSPECTION CONNECTING ROD

Inspect the bea ring inserts for damage or separation . Clean all oil from the bearing inserts and crankpins. Put a piece of plastigauge on each crankpin avoiding the oi l hole.

 

 

I nstal l the bearing caps and rods on the correct crankpins, end tighten them evenly.

 

TORQUE: 30-34 N·m

(3.0-3.4 kg.m, 22-25 ft lbl

 

NOTE

 

Do not  rotate  the crankshaft durin g inspec­ tion.

 

 

Remove tho caps and measure the compressed plastigauge at its widest point on each crankpin to determine the oil clearance.

SERVICE LIMIT:0.07 mm (0.003 in l

 

(11 PLASTIGAUGE

 

 

MAIN BEARINGS

 

Measure the main journal O.D. and record it.

 

Measure the main jou rnal bearing 1.0. in the crank·

cue and record it,

Calculate  the clearance  bet\Neen  the mai n  journal and the mein bearing,

 

SERVICE LIMIT:0.06 mm (0.002 in)

 

 

BEARING SELECTION

 

If  oil cleerance is beyond tolerance, select replace­ ment bearings as follows :

 

CONNECTING ROD BEARING INSERTS

 

Determine  and record the correspondi ng rod  1.0.

code number.

 

NOTE

 

N umbers  1 or 2 on the connecti ng rods are the codes for the connecti ng rod 1.0.

CRANKSHAFT/TRANSMISSION

VTSO OC

Determ ine  and  record  the correspondi ng cran kpin

1.1. code number (or meas.ore the cran kpi n 0.0.) .

 

NOTE

 

Letters A or B on crank weight are the codes used for crank pin 0.0.from left side.

 

 

Cross ref erence the crankpin and rod codes to deter· mine the replacement bearing color.

(1) CRANK PIN 0.0.CODE

 

 

CONNECTING ROO 1.0.CODE NO. 1 2 •3.000- .008 mm •3.008- .016 mm   CRANK PIN O.O. CODE A 39.982- B ro wn Black   8 39.974- 39.982 mm   Block   B l ue

39.990 mm

 

BEARING INSER T THICKNESS

Blue:  1.495-1.499 mm (0.0589-0.0590 in)

Black: 1.491-1.495 mm (0.0578-0.058-9 in)

Brown: 1.487-1.491 mm  (0.0585-0.0587 in)

 

 

MAIN BEAR ING INSERTS

 

Determine and record the corresponding main jour· nal O.D.codes, (or measure the mai n jou rnal O.D.).

 

( I ) MA IN JOURNAL

O.D. COOE

 

 

 

Measure the crankcase main journal l.D. and record

i t.

 

 

Cross reference the case l.D. and jou rnal code to

MAIN JOURNAL 0.0. CODE 1 2 39.992- 39.984- 40.000 mm 39.992 mm (1.5744- (1.5741- 0.1575 i n) 1.5744 in)     CRANK· CASE 1.0. 44.010- 44.020 mm (1.7326- 1.7331 in )   BROWN   BLACK 44.000- 44.0IO mm {1.7322- 1.7326 in)   BLACK   BLUE

determine the replacement bearing.

 

 

MAIN BEAR ING INSERT THICKNESS: BROWN (MARK C):  1.989-1.999 mm

(0.0783-0.0787 in)

BLACK (MARK Bl: 1.994-2.004 mm

(0.0785-0.7798 in)

BLUE (MARK A):   1.999-2.009 mm

(0.0787-0.0791 in)

 

 

MAIN JOURNAL BEARING REMOVAL

 

Remove the main bearings from the crankcase.

 

 

 

(1) DRIVER' A 07749-0010000

 

(2) MAIN BEARING REMOVER ATTACHMENT  07946-MF50100

CRANKSHAFT/TR ANSMESSION

VTSOOC

MAIN BEARING INSTALLATION

 

Apply  moly bdenum  disulf ide  .grease  to  the  outer surface of the main bearings.

Align the tab on the bearing with the groove i n the crankcase and press the bearing  into the crankcase.

 

NOTE

(1) MAIN BEARING DRIVER ATTACHMENT   (2) MARK

(5) DRIVER HANDLE A

07749-0010000

 

 

CAUTIOH

I Be careful not to d111T1age the bearings.

CONNECTI NG ROD INSTALLATION

 

I nstall  the bearing inserts on the rods and caps.

 

Align  the  boss  on  the bearing with  the groove in the rod or cap. Apply molybdenum disulfide grease to the bearings.

NOTE

(3) TAB   (4) DRAW TWO LINES  (6) MAIN-BEARING DRIVER

ATTACHMENT 07946-MF50200

(1) CONNECTING ROD    r;;;;;l2) MOLYBDENUM BEARING                ti DISULFIDE GREASE

(31GROOVE(4)  BOSS

 

 

I nstall the rods and caps on the crankshaft. Be sure each part is installed i n its original position, as noted during removal.

Tigh ten the cap nuts.

 

TORQUE:  30-34 N·m

(3.0-3.4 kg-m,22-25 ft-lb)

 

 

 

1 3 - 10

CRANKSH AFT INSTALLATION

 

Install the crankshaft onto the left crankcase.

Install  the dowel  pins  and  assemble  the  crankcase (page 12-4).

 

 

TR ANSMISSION  REMOVAL

Separate the crankcase (page 12-2).

Place  the  lef t crankcase down  on  i ts outer surface. Remove the crankshaft  ( page 13-4).

Remove the final gear.

 

Remove the mainshaft,counter shaft, and shift fork togethe r as an assembly.

 

 

 

 

 

{1) MAINSHAFT

 

 

 

13- 1 1

(2) COUNTER SHAFT

 

(3) SHIFT

FOR K

 

 

 

TRANSM ISSION DISASSEMB LY

 

Sei>anne  the  shift  forks,  shaft,  mainshaft  and oountershaft essemblie$ from each other.

 

 

TRANSMISSION INSPECTION

 

Check the 90ar dogs, hole:& and teeth for exc:e11iva or a1>norm11 w.ar, or ovidenQO of in11.1fficient lubrl· cation.

Measu re the 1.0. of each gear.

 

SERVICE LIMITS

M511Hrs:                     29.08 mm  (1.144 In)

Me g..n:               28.08 mm (1.105 In)

C1,C2, C3, C4 gears: 28.04 mm (1.104 lnl

 

Measure ltle 1.0. and 0.0. of each gea r bushi ng.

(1) SHIFT FORK/SHAFT          (2)  UNTERSHAFT

 

SERVICE LIMITS:

Mli bulhlng 0.0.: M6 bulhlng 0.0.: C1, C2, C3,C4

buifling 0.0.:

M6 butlling l.D.: C2,C4 bushing 1.0.:

 

13- 12

28.94 mrn (1.139 i11I

27.94 mm ( 1.100 inl

 

27.94 mm {1.100 inl

26.06 mm (0.987 inl

25.04 mm (0.986 int

 

 

 

Measure  the 0.0. of the m1ind11ft and coun11r­

shaft

 

SE RVICE LIMITS:

A (et M6 bushing): B (nC2 bushing ): C (et C4 bu1hin1J:

 

24.90 mm  (0.980 In )

24.90 mm  (0.980 In )

24.90 m m (0.980 inl

 

Calculate the clearW'!ce between the gear W'!d ge1r shaft  or  bushing.

 

SERVICE LIMITS:

MB, 8 1111er to MB,8 bu1hing:

0.10 mm (0.004 in)

M5 bulhing to 11wft:

C1gear to C1bushing: C1 bushing to shaft:

C2 "'tt1 C2 bushing :

C3 111'to C3 bushing:

C4 111r to C4 bushint: C2, C4 bllllllng to •hdt:

0.08 mm (0.002 in)

0.10 mm (0.004 In)

0 10 mm (0.004in)

0.10 mm (0.004 in)

0.10 mm (0.004 In)

0.10 mm (0.004 In)

O.o& mm (0.002 In)

 

TRANSMISSION  ASSEMBLY

 

Mlinlhsft

Check the gem for freedom of movement of rota­ tion on the shaft.

Check the snap rings are seated In the !J'OOYH.

 

 

M6

M4

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