Service limit: 0. 03 mm (0. 001 in)

 

 

29.0 mm

 

(1.14 in)

 

 

INSTALLATION

 

 

6.0 mm

 

(0.24 in)

 

Apply molybdenum oil solution to the connecting rod big
[1]
end sliding surface.
Apply molybdenum oil solution to the crankshaft main
journal bearing sliding surface.
Install the crankshaft [1] into the right crankcase.
Assemble the crankcase (page 14-18).

 

14-6

CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER

MAIN JOURNAL BEARING

 

BEARING INSPECTION

 

Remove the following:
[1]
–	Crankshaft (page 14-6)
–	Transmission (page 14-10)
		INSIDE
– Balancer shaft (page 14-14)

Clean off any oil from the bearings.

 

Check the main journal bearings [1] for unusual wear,			90°
damage or peeling and replace them if necessary.
						OUTSIDE
MAIN JOURNAL OIL CLEARANCE
				MEASUREMENT
Measure and record the main journal bearing I.D. at
				POINT
between the bearing groove and crankcase outside end
of the bearing, and 90 degrees to the index mark [2].	[2]

 

Clean off any oil from the crankshaft journals. Measure and record the crankshaft main journal O.D.

SERVICE LIMIT: 33.975 mm (1.3376 in)

 

Calculate the oil clearance between the crankshaft main journal and main journal bearing.

 

SERVICE LIMIT: 0.075 mm (0.0030 in)

 

If the clearance exceeds the service limit, select the main journal bearing (page 14-7).

 

BEARING SELECTION
Remove the following:
	[1]
–	Crankshaft (page 14-6)
–	Transmission (page 14-10)
– Balancer shaft (page 14-14)
Set a special tool and hydraulic press on the outside of
the crankcase.
TOOLS:
[1] Driver, 30 x 36 mm	07HMF-KR10101
[2] Base, 42 mm	07GAF-SD40200

 

[2]

 

Press the main journal bearings [1] toward the inside of the crankcase.

 

 

[1]

 

14-7

CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER

Measure and record the crankcase main journal bearing support I.D. at 90 degrees to the index mark [1].

SERVICE LIMIT: 38.036 mm (1.4975 in)

 

90°

 

	[1]
Depending upon the results of the above
		[1]
measurements there are four possible scenarios for
main journal bearing selection:

• Crankshaft and crankcase are replaced

• Crankcase only is replaced

• Crankshaft only is replaced

• Main journal bearings only are replaced

 

Carefully refer to the following instructions and tables for main journal bearing selection.

 

Record the bearing support I.D. code [1] letter.

Letters A, B or C on each crankcase is the code for the crankcase main journal bearing support I.D.

 

Cross-reference the crankshaft and crankcase codes to determine the replacement bearing color.

 

BEARING SUPPORT		MAIN JOURNAL O.D.
I.D. CODE	BEARING SUPPORT I.D.	33.985 – 34.000 mm	33.975 – 33.985 mm
(1.3380 – 1.3386 in)
(Crankcase replaced)		(1.3376 – 1.3380 in)
	(Crankshaft replaced)
	38.000 – 38.006 mm	C (Brown)	B (Black)
A	1.996 – 1.999 mm	1.999 – 2.002 mm
(1.4961 – 1.4963 in)
	(0.0786 – 0.0787 in)	(0.0787 – 0.0788 in)
	38.006 – 38.012 mm	B (Black)	A (Blue)
B	1.999 – 2.002 mm	2.002 – 2.005 mm
(1.4963 – 1.4965 in)
	(0.0787 – 0.0788 in)	(0.0788 – 0.0789 in)
	38.012 – 38.018 mm	A (Blue)	O.S. G (Pink)
C	2.002 – 2.005 mm	2.005 – 2.008 mm
(1.4965 – 1.4968 in)
	(0.0788 – 0.0789 in)	(0.0789 – 0.0791 in)
	38.018 – 38.024 mm	O.S. G (Pink)	O.S. F (Yellow)
–	2.005 – 2.008 mm	2.008 – 2.011 mm
(1.4968 – 1.4970 in)
	(0.0789 – 0.0791 in)	(0.0791 – 0.0792 in)
	38.024 – 38.030 mm	O.S. F (Yellow)	O.S. E (Green)
–	2.008 – 2.011 mm	2.011 – 2.014 mm
(1.4970 – 1.4972 in)
	(0.0791 – 0.0792 in)	(0.0792 – 0.0793 in)
	38.030 – 38.036 mm	O.S. E (Green)	O.S. D (Red)
–	2.011 – 2.014 mm	2.014 – 2.020 mm
(1.4972 – 1.4975 in)
	(0.0792 – 0.0793 in)	(0.0792 – 0.0795 in)

 

14-8

CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER

 

BEARING THICKNESS:

 

O.S. D (Red): Thick

 

O.S. E (Green):

O.S. F (Yellow):

 

O.S. G (Pink): Middle

 

A (Blue):

B (Black):

C (Brown): Thin

 

BEARING INSTALLATION

 

Apply engine oil to new bearing [1] surface.

Set new bearings to the metal installer as shown.

 

TOOL:

 

Metal installer set 070MF-KYJ0100

 

Tighten the bolts [2] alternately in several steps.

 

Set the bearings [1] and special tools assembly on inside of the crankcase, fitting the bearing edge in the crankcase main journal.

Align the mating line of the bearings with the index mark [2] on the crankcase as shown.

 

 

Set the crankcase and special tools on the hydraulic press.

 

TOOLS:

 

[1] Metal installer set 070MF-KYJ0100

 

[2] Base, 42 mm 07GAF-SD40200

 

Make sure the metal installer mating line is aligned with the index mark on the crankcase.

 

IDENTIFICATION COLOR

 

4.0 mm

 

(0.16 in)

 

 

				[2]
[1]

 

 

[1]

 

[2]

[1]

 

 

[2]

 

14-9

CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER

 

Press the bearings [1] until the metal installer flange [2] is fully seated.

[1]

 

 

Make sure the bearing mating line is aligned with the index mark on the crankcase.

 

Check the oil clearance (page 14-7).

After selecting new bearings, recheck the oil clearance.

 

Incorrect clearance can cause severe engine damage.

 

Install the following:

 

– Crankshaft (page 14-6)

– Transmission (page 14-11)

– Balancer shaft (page 14-14)

 

TRANSMISSION

 

REMOVAL/DISASSEMBLY

 

Separate the crankcase halves (page 14-4).

 

Pull the shift fork shaft [1] and remove it from the shift forks.

 

Remove the shift forks [2] and shift drum [3].

 

 

[3]

 

Remove the mainshaft assembly [1] and countershaft assembly [2] together.

 

[2]

 

Align

 

 

[1]

[2]

 

[1]

 

 

[2]

 

 

14-10