BALANCER/TRANSMISSION BEARING

 

Remove the following:

 

– Crankshaft (page 14-6)

– Balancer shaft (page 14-14)

– Transmission (page 14-10)

 

RIGHT CRANKCASE SIDE

 

Remove the bolts [1] and mainshaft bearing setting plate [2].

 

Drive out the mainshaft bearing [3], shift drum bearing [4] and balancer shaft bearing [5].

 

 

Remove the countershaft bearing [1] using the special tools.

 

TOOLS:
[2] Bearing remover set, 17 mm	07936-3710300
Remover handle	07936-3710100
[3] Remover weight	07741-0010201

 

[5]

 

[3]

 

[2]

[3]

 

[1]

[4]

[1]

 

 

[2]

 

14-15

CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER

 

Drive in new bearings into the right crankcase until they are fully seated using the special tools.

TOOLS:
[1] Mainshaft bearing (marked side facing up):
[2] Driver	07749-0010000
[3] Attachment, 52 x 55 mm	07746-0010400
[4] Pilot, 20 mm	07746-0040500
[5] Countershaft bearing (sealed side facing down):
Driver	07749-0010000
Attachment, 37 x 40 mm	07746-0010200
Pilot, 17 mm	07746-0040400
[6] Shift drum bearing (marked side facing up):
Driver	07749-0010000
	[1]
Attachment, 42 x 47 mm	07746-0010300
After installation, apply engine oil to each bearing
rotating area.
Drive in a new balancer shaft bearing into the right
crankcase until it is fully seated using the special tools.
TOOLS:
[1] Balancer shaft bearing (marked side facing up):
[2] Driver	07749-0010000
[3] Attachment, 42 x 47 mm	07746-0010300
[4] Pilot, 20 mm	07746-0040500

After installation, apply engine oil to the bearing rotating area.

 

[1]

 

Apply locking agent to the mainshaft bearing setting plate bolt [1] threads (page 1-15).

Install the setting plate [2] with its "OUTSIDE" mark [3] facing out.

 

Install and tighten the bolts securely.

 

[1]

 

LEFT CRANKCASE SIDE

 

Remove the snap ring [1].

Remove the countershaft oil seal [2] from the left crankcase.

[2] [3]/[4]

 

[5]

 

[6]

 

 

[2] [3]/[4]

 

 

[3]

 

 

[2]

 

 

[1]

 

 

[2]

 

14-16

CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER

 

Drive out the countershaft bearing [1].

 

 

Remove the mainshaft needle bearing [1] using the special tools.

 

TOOLS:
[2] Bearing remover set, 17 mm	07936-3710300
Remover handle	07936-3710100
[3] Remover weight	07741-0010201

 

 

Remove the balancer shaft bearing [1] using the special tools.

 

TOOLS:
[2] Bearing remover set, 20 mm	07936-3710600
[3] Remover handle	07936-3710100
[4] Remover weight	07741-0010201

 

 

Drive in new bearings into the left crankcase until they are fully seated using the special tools.

 

TOOLS:
[1] Mainshaft needle bearing:
[2] Driver	07749-0010000
[3] Attachment, 28 x 30 mm	07946-1870100
[4] Pilot, 17 mm	07746-0040400

[5] Countershaft bearing (marked side facing up):

 

Driver	07749-0010000
Attachment, 52 x 55 mm	07746-0010400
Pilot, 22 mm	07746-0041000

[6] Balancer shaft bearing (marked side facing up):

 

Driver	07749-0010000
Attachment, 42 x 47 mm	07746-0010300
Pilot, 20 mm	07746-0040500

 

After installation, apply engine oil to each bearing rotating area.

 

[1]

[1]

 

 

[3]

[2]

[2]

 

 

[3]

 

[4]

[1]

[2]

 

[5]

 

[3]/[4]

 

 

[1]					[6]

 

14-17

CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER

 

Apply grease to a new countershaft oil seal [1] lips.

 

Install the countershaft oil seal with its marked side facing up, until it is flush with the snap ring groove.

 

Make sure the snap Install the snap ring [2]. ring is firmly seated

in the groove.

 

[1]

 

 

[2]

 

CRANKCASE ASSEMBLY

 

Clean the oil passages of each crankcase using a compressed air.

 

Check the oil passage for clogs.

 

 

Clean the left and right crankcase mating surfaces thoroughly, being careful not to damage them and check for damage.

 

Apply a light but through coating of sealant (Three bond 1207B, 1215 or equivalent) to left crankcase mating surface except the oil passage area.

 

 

Apply engine oil to a new O-ring [1].

 

Install the dowel pins [2] and O-ring.

 

[2]

 

 

[1]/[2]

 

 

14-18

CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER

 

Do not force the Install the left crankcase [1] on the right crankcase [2], crankcase halves being careful not to damage the oil seal lips.

 

together, If there is excessive force required, something is wrong. Remove the left crankcase and check for misaligned parts.

 

 

[2]

 

Install the crankcase bolts [1].

 

Tighten the bolts in a crisscross pattern in 2 or 3 steps.

 

[1]

 

Be careful not to	Install the woodruff key [1] into the balancer shaft
damage the key	groove.
groove and
balancer shaft.

 

Align the balancer gear [1] and balancer sub gear [2] holes and install a 3 mm (0.12 in) pin [3] into the hole.

[1]

 

[1]

 

[3] [2]

 

 

[1]

 

 

14-19