PREVENCIÓN DE INCENDIOS

158

Specification

Item Standard Service Limit

Crankshaft, Connecting Rod:

Connecting rod big end side clearance

Connecting rod big end Radial clearance

0.5mm ± 0.1 0.006~0.019

0.5mm ± 0.2 0.07mm Crankshaft runout: Right TIR 0.04mm or less TIR 0.10mm Left TIR 0.04mm or less TIR 0.08mm

Transmission:

Shift fork ear thickness Shift fork ear thickness (left)

5.03-5.13 5.69-5.79

4.93 5.59 Gear shift fork groove width

Gear shift fork groove width (left)

5.33± 0.1 6.00± 0.1

5.43± 0.1 6.10± 0.1

Shift fork guide pin diameter 4.7625 4.75

159

Crankcase

Crankcase Disassembly

 Remove the engine (see Engine Remove/Installation chapter).

 Set the engine on a clean surface and hold the engine steady while parts are removed.  Remove:

o Engine Covers (see relevant chapter) o Primary Gear (see Clutch chapter) o Balance shaft Gear (see this chapter) o Clutch (see Clutch chapter)

o Starter Motor (see Electrical System chapter) o Alternator rotor (see Electrical System chapter) o Trigger disk (see Electrical System)

o Cylinder and Gasket (see Top End chapter) o Piston (see Engine Top End chapter)

o Camshaft Chains and Guides (see Engine Top End chapter) o External shift mechanism (see this chapter)

o Cassette plate with gears and shift mechanism (see this chapter)  Remove the crank case bolts back from 13 to 1

160 There are two ring dowels on the crankcase mating surface,

using a plastic mallet tap lightly around the crankcase mating surface until free.

161  Remove the baffle plate.

 Remove the 9 centre plate bolts from 9 back to 1.

 Remove the crank shaft with the centre plate by hand.

Crankcase Assembly

Caution: Right crankcase, left crankcase, and centre plate are machined at the factory in the assembled state, so the crankcase halves must be replaced as a set.

162  Chip off the old gasket from the mating surfaces of the crankcase halves.

 Using compressed air, blow out [A] the oil passages in the crankcase halves and centre plate.  With a high-flash point solvent, clean off the mating surfaces of the crankcase halves and wipe dry.

Warning: Clean the engine parts in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area; this includes any appliance with a pilot light. Do not use gasoline or a low-flash point solvent to clean parts. A fire or

explosion could result.

 Using a press and the bearing drive set, install new bearings until they bottom out on the crankshaft and cases if required. Do not replace half of the bearing and not the other half.

 Ensure all oil seals are correctly installed and seated, if any wear is visible replace.  Install the crankshaft by hand with the

centre plate installed on the crank.

 Install the 9 centre plate bolts and tighten in the sequence shown (one to nine).

Torque – Centre Plate Bolts: 25Nm

 Install the baffle plate and bolts and tighten.

Torque – Baffle Plate Bolts: 5Nm

 Be sure the mating surfaces of the crankcase halves are clean and dry.

 Check to see the two crankcase dowels pins [A] are in place on the right crankcase half. If either has been removed, replace it with a new one.

 Apply liquid gasket to the mating surface of the left crankcase half.

Sealant – 3 bond gasket sealant

 Install the left hand crankcase.

 Ensure all seals are not damaged during installation; use a feeler gauge if necessary to feed the lip seals on.

 Tighten the crankcase bolts in the order listed.

Torque – Crankcase Bolts: 48Nm (Excluding the 8th bolt) Torque – Crankcase Gearbox Bolt: 12Nm (The 8th bolt)

163  Constantly check the alignment of the two crankcase halves, and the position of the balance shaft.

The front and rear of the crankcase must be pushed together evenly.  Check:

 Crankshaft and balancer shaft turn freely.

 If any of the shafts do not turn freely, split the crankcase to locate the problem.  Install: Remove the crank shaft with the centre plate by hand.

 Primary Gear (see Clutch chapter)  Balance shaft Gear (see this chapter)

 Cassette plate with gears and shift mechanism (see this chapter)  External shift mechanism (see this chapter)

 Clutch (see Clutch chapter)

 Trigger disk (see Electrical System)

 Alternator rotor (see Electrical System chapter)  Starter Motor (see Electrical System chapter)  Piston (see Engine Top End chapter)

 Cylinder and Gasket (see Top End chapter)

 Camshaft, Chains and Guides (see Engine Top End chapter)  Engine Covers (see relevant chapters)

 Install the engine (see Engine Removal/Installation chapter).  Install the engine sprocket (see Final Drive chapter)

164

Crankshaft Removal

 See Crankcase Disassembly

 To Split the centre plate remove the two main bolts.

 Tap lightly around the joint face with a plastic hammer and split the centre plate, remove.

Crankshaft Installation

 See Crankcase Assembly

 To join the centre plate ensures the two dowels are in place and align the main centre bearing cir clip with the groove in the plates.

 Ensure the grub screw is installed in the centre plate.

 Tap the top and the bottom with a plastic hammer; constantly check the alignment of the two halves.

 Tighten the two centre plate bolts.

Torque – Centre Plate Split bolts: 48Nm Crankshaft Disassembly

 Use a bearing puller to remove the inner bearing runners on the other crankshaft outer left hand and right hand side.

Note: The crankshaft is a welded assembly; therefore it cannot to disassembled and must be replaced as a whole unit.

Crankshaft Assembly

 Using a bearing press tool press the bearing inner runner fully home on the crankshaft.

Connecting Rod Big End Radial Clearance

 Set the crankshaft on V blocks, and place a dial gauge [A] against the connecting rod big end.

 Push [B] the connecting rod first towards the gauge and then in the opposite direction. The Difference between the two gauge readings is the radial clearance.

 If the radial clearance exceeds the service limit, the crankshaft assembly must be replaced.

Clearance – Big end Radial: Standard: 0.006~0.019 Service Limit: 0.07mm Connecting Rod Big end Side Clearance

 Set the crankshaft on V blocks.

 Measure the side clearance [A] of the connecting rod with a thickness gauge.

165  If big end side clearance exceeds the service limit, the crankshaft assembly must be replaced.

Clearance – Connecting Rod Big End Side Clearance: Standard: 0.40~0.60mm Service Limit: 0.70mm

Crankshaft Alignment

 With the crankshaft on V blocks, turn the crankshaft slowly and measure runout at each of the locations shown [A] and [B].

Runout – Crankshaft Right Half:

Standard TIR 0.04mm or less. Service limit: TIR 0.10mm

Runout – Crankshaft Left Half: Standard TIR 0.04mm or less. Service Limit: TIR 0.08mm

 If runout at either location exceeds the service limit, replace the crankshaft assembly.

Transmission

Transmission shift pedal

 Adjust the shift pedal position from the foot peg to suit you.

 The standard shift pedal position is about 40mm below the foot peg top.

External Shift Mechanism Removal

 Drain the engine oil (see Engine Lubrication System chapter)

 Remove gear shift pedal assembly.

 Remove clutch cover (See Clutch chapter)  Remove the two allen head retainer bolts.

 Align the neutral cut out of the detent wheel with the selector fork; pull the fork back away from the detent wheel so it can slide past.

166  Remove the external shift assembly.

 Remove the snap link arm retainer bolt; remove snap link arm.

 Remove the detent wheel retainer bolt; remove the detent wheel.

External shift Mechanism Installation

 Be sure the dowels are correctly installed in the shift drum [A]

 Apply Threebond 1305 to the threads of the shift drum cam bolt; install detent wheel and tighten retainer bolt.

Torque – Shift Drum Cam Bolt: 12Nm, Threebond 1305

167

Torque – snap link arm bolt: 15Nm, Threebond 1305

 Ensure selector fork is assembled as detailed below.

 Align the neutral cut out of the detent wheel with the selector fork; pull the fork back away from the detent wheel so it can slide past and install.

Torque – shift mechanism bolts: 12Nm

External Shift Mechanism Inspection

 Check the shift shaft for bending or serrations [A] for damage

 If the shaft is bent, straighten or replace it. If the serrations are damaged, replace the shaft.

 Check the springs [B] for breaks or distortion.

 If the springs are damaged in any way, replace them.

 Check the shift mechanism arm [C] for distortion.

 If the shift mechanism arm is damaged in any way, replace the shift shaft

assembly.

Transmission Removal

 Remove the clutch.

 Remove External Shift Mechanism (see this chapter)

168  Remove the cassette plate retainer bolts.

 Remove the cassette plate as a single unit.

Transmission Installation

 Apply a small amount of engine oil to the transmission gears, bearings, shaft journals, and shift fork fingers.  Install the cassette plate assembly

ensuring the output shaft is correctly aligned.

 Tighten the cassette plate bolts.

Torque – Cassette plate bolts: 25Nm Transmission Disassembly

 Put gearbox in neutral position

 Remove the Transmission (see Transmission Removal)

 Hold the transmission shafts and selector drum, tap the cassette plate lightly with a plastic hammer and remove.

169  Remove the gears and spacers in the sequence shown, using the outside circlip pliers, remove the

circlips [30] and disassemble the transmission shafts completely.

Transmission Shaft Assembly

 Replace any circlips that were removed with new ones.

 Install the gears, spacers, and circlips in the order shown.

 Assemble the shift fork to the main and lay shafts at 90˚ to the axial direction of the main shaft and lay shaft.

 Insert the lay shaft main shaft and selector drum into the cassette plate as one unit, use a plastic mallet if required to mate the cassette plate home.

170  Visually inspect the shift forks, and replace any fork that is bent. A bent fork could cause difficulty in

shifting, or allow the transmission to jump out of gear when under power. 90˚ [A].

Shift Fork Ear/Gear Shift Fork Groove Wear

 Measure the thickness [A] of the shift fork ears.

 If the thickness of a shift fork ear is less than the service limit, the shift fork must be replaced.

Shift Fork Ear Thickness Standard: 5.03~5.13mm Service Limit: 4.93mm Shift Fork Ear Thickness (left) Standard: 5.79~5.69mm Service Limit: 5.59mm

 Measure the width [A] of the gear shift grooves.

 If a gear fork groove is worn over the service limit, the gear must be replaced.

Gear Shift Fork Groove Width Standard: 5.33 ± 0.1mm Service Limit: 5.43 ± 0.1mm

Gear Shift Fork Groove Width (left) Standard: 6.00 ± 0.1mm

Service Limit: 6.10 ± 0.1mm

Shift Fork Guide Pin/Shift Drum Groove Wear

 Measure the diameter [A] of each shift fork guide pin, and measure the width [B] of each shift drum groove.

 If the guide pin on any shift fork is less than the service limit, the pin must be replaced

Shift Fork guide Pin Diameter Standard: 4.7625mm Service Limit: 4.75mm

 If any shift drum groove is worn over the service limit, the drum must be replaced.

Shift Fork Guide Groove Diameter Standard: 4.9mm Service Limit: 5.00mm

B A

171

Gear Dog/Dog Recess Damage

 Visually inspect the gear dogs [A], and recesses [B].

 Replace any damaged gears or gears with excessively worn dogs, or recesses.

Balancer

Balancer shaft Removal

 Split the crankcase (see Crankcase Disassembly)  Lift the balancer shaft [A] out of the right-hand

crankcase half.

Balancer Shaft Installation

 See Crankcase Assembly.

 Install by hand ensuring spacer is in position.

Balance Gear Removal

 Remove the clutch cover (see clutch Cover Removal).

B

B

B A

172  Use a gear holder or if one is not available use a copper coin between the primary and balance gear

to lock the engine rotation.

 Insert an M8 bolt into the balance gear location hole [A] this will lock the anti backlash spring in place.

 Remove:

o Balance Gear Nut o Balance Gear Washer

 Remove the Balance gear, with the anti-backlash gear and spring.  Remove woodruff key.

Balance Gear Installation

 Install:

 Woodruff key [A]

 Balance Gear assembly [A] ensuring dots line up.  Balance Gear Washer [B]

173  Use a gear holder or if one is not available use a copper coin between the primary and balance gear

to lock the engine rotation.  Tighten Balance gear nut.

Torque – 122Nm Threebond 1305

 Install the clutch cover (see clutch Cover Removal).

Balancer Shaft Gear Disassembly

 Use the Balance Shaft Gear Holder tool and remove the m8 nut inserted during engine disassembly. Allow the spring to slowly unwind, separate the gears.

 The dowels can be removed if required.

Balancer Shaft Gear Assembly

 Assembly by hand on the Balance Shaft Gear Holder tool in order shown.

 Use the Balance Shaft Gear Holder tool, slowly apply tension to the spring then when the two holes align insert an m8 nut.

174

Ball and Needle Bearing Replacement

Caution: Do not remove the ball or needle bearings unless it is necessary. Removal may damage them.  Using a press or puller, remove the ball and/or needle bearings.

Note: In the absence of the above mentioned tools, satisfactory results may be obtained by heating the case to approximately 75˚C max, and tapping the bearing in or out.

Caution: Do not heat the case with a torch. This will warp the case.

 Using a press and a bearing drive, install the new bearing until it stops at the bottom of its housing.

Ball and Needle Bearing Wear

Caution: Do not remove the bearings for inspection. Removal may damage them.  Check the ball bearings.

 Since the ball bearings are made to extremely close tolerances, the wear must be judged by feel rather than measurement. Clean each bearing in a high-flash point solvent, dry it (do not spin the bearing while it is dry), and oil it with engine oil.

 Spin the bearing by hand to check its condition.

 If the bearing is noisy, does not spin smoothly, or has any rough sports, replace it.  Check the needle bearings.

 The rollers in a needle bearing normally wear very little, and wear is difficult to measure. Instead of measuring, inspect the bearing for abrasion, colour change, or other damage.

 If there is any doubt as to the condition of a needle bearing, replace it. 

Oil Seal Inspection

 Inspect the oil seals.

 Replace it if the lips are misshapen, discoloured (indicating that the rubber has deteriorated), hardened or otherwise damaged.

175

Wheels/Tyres

Exploded View ... 171 Specification ... 178 Wheels ... 179 Front Wheel Removal ... 179 Front wheel Installation ... 179 Rear Wheel Removal ... 180 Rear wheel Installation ... 180 Front wheel Disassembly ... 180 Front wheel Assembly ... 181 Rear wheel Disassembly ... 181 Rear wheel Assembly ... 182 Wheel Inspection ... 182 Spoke Inspection ... 182 Rim Inspection ... 182 Axle Inspection ... 183 Wheel Balance ... 183 Wheel Balance Inspection ... 183 Wheel Balance Adjustment ... 183 Tyres ... 184 Air Pressure Inspection / Adjustment ... 184 Tyre Inspection ... 184 Tyre Removal ... 185 Tyre Installation ... 185 Hub Bearings (wheel Bearings ... 186 Bearing Removal ... 186 Bearing Installation ... 186 Bearing Inspection ... 186

176

177 REF.

NO.

PART DESCRIPTION TORQUE

(NM)

REMARKS

1 REAR WHEEL, CARBON FIBRE, BLACK STANDARD REAR WHEEL FOR

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