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Crankshaft I Transmission






Table of Contents


 

 


Exploded View................................................................. 8-2

Specifications.................................................................. 8-4

Crankcase Splitting......................................................... 8-6

Crankcase Splitting..................................................... 8-6

Crankcase Assembly.................................................. 8-6

Crankshaft and Connecting Rods................................... 8-8

Crankshaft Removal.................................................... 8-8

Crankshaft Installation................................................ 8-8

Connecting Rod Removal........................................... 8-8

Connecting Rod Installation........................................ 8-8

Connecting Rod Big End Bearing

Insert/Crankpin Wear................................................ 8-11

Crankshaft Main Bearing Insert/Journal Wear., 8-12

Crankshaft Side Clearance....................................... 8-14

Alternator Chain / Alternator Shaft /

Starter Clutch............................................................. 8-15

Alternator Chain Adjustment..................................... 8-15

Alternator Chain Removal......................................... 8-15

Alternator Chain Installation...................................... 8-16

Alternator Shaft, Starter Clutch Removal.................. 8-16

Alternator Shaft, Starter Clutch Installation.............. 8-17

Starter Clutch Disassembly...................................... 8-17

Starter Clutch Assembly........................................... 8-17

Alternator Shaft Chain Wear..................................... 8-17

Chain Guide Wear.................................................... 8-18

Starter Clutch Inspection.......................................... 8-18

Starter Motor Idle Gear.................................................. 8-19

Starter Motor Idle Gear Removal............................. 8-19

Starter Motor Idle Gear Installation.......................... 8-19

Transmission................................................................. 8-20

Shift Pedal Removal................................................. 8-20

Shift Pedal Installation.............................................. 8-20

External Shift Mechanism Removal......................... 8-20

External Shift Mechanism Installation...................... 8-21

External Shift Mechanism Assembly....................... 8-22

Transmission Shaft Removal................................... 8-22

Transmission Shaft Installation................................ 8-22

Transmission Disassembly..................................... 8-22

Transmission Assembly........................................... 8-22

Shift Drum and Fork Removal.................................. 8-23

Shift Drum and Fork Installation............................... 8-23

Shfit Drum Disassembly........................................... 8-24

Shfit Drum Assembly................................................ 8-24


Exploded View


T1: 12 N-m (1.2 kg-m, 104 in-lb) T2: 25 N-m (2.5 kg-m, 18.0 ft-lb) T3: 44 N-m (4.5 kg-m, 33 ft-lb) T4: 27 N-m (2.8 kg-m, 20 ft-lb) T5: 20 N-m (2.0 kg-m, 14.5 ft-lb) T6: See the text. T7: 15 N-m (1.5 kg-m, 11.0 ft-lb) T8: 4.9 N-m (0.50 kg-m, 43 in-lb) T9: 9.8 N-m (1.0 kg-m, 87 in-lb) T10: 125 N-m (13 kg-m, 94 ft-lb)

1. Upper Alternator Chain Tensioner

2. Lower Alternator Chain Tensioner EO: Apply engine oil.

L: Apply a non-permanent locking agent. M: Apply molybdenum disulfide grease. R: Replacement Parts SS: Apply silicone sealant. G: Apply grease.


Specifications


 

 


Item
Standard

Service Limit


 

 


Alternator Chain:

Alternator chain 20 link length Crankshaft, Connecting Rods:

Connecting rod big end side clearance

Connecting rod big end bearing insert/crankpin clearance

Crankpin diameter:

Marking None

о

Connecting rod big end bore diameter: Marking None

о

Connecting rod big end bearing insert thickness:

Brown Colorless Blue

158.8 - 159.2 mm

0.13 - 0.38 mm 0.036 - 0.066 mm 34.984 - 35.000 mm 34 984 - 34.992 mm 34.993 - 35.000 mm 38.000 - 38.016 mm 38.000 - 38.008 mm 38.009 - 38.016 mm

159.8 mm 0.6 mm 0.10 mm 34.96 mm

1.475 - 1.480 mm 1.480 ~ 1.485 mm 1.485 - 1.490 mm


 

 


Connecting rod big end bearing insert selection:
Con-rod Big End Bore Diameter Marking Crankpin Diameter Marking Bearing Insert
Size Color Part Number
None О Brown 92028-1714
None None Colorless 92028-1713
О О
О None Blue 92028-1712

 

 


Connecting Rod Bolt Stretch (Usable Range) New connecting rod Used connecting rod Crankshaft side clearance Crankshaft runout Crankshaft main bearing insert/

journal clearance Crankshaft main journal diameter: Marking None

Crankcase main bearing bore diameter: Marking о

None

Crankshaft main bearing insert thickness:

Brown Colorless Blue

0.20 - 0.32 mm 0.24 - 0.36 mm 0.05 - 0.20 mm TIR 0.02 mm or less

0.020 - 0.044 mm 32.984 - 33.000 mm 32.984 ~ 32.992 mm 32.993 - 33.000 mm 36.000 - 36.016 mm 36.000 - 36.008 mm 36.009 - 36.016 mm

0.40 mm TIR 0.05 mm 0.07 mm 32.96 mm

1.490 - 1.494 mm 1.494 - 1.498 mm 1.498 - 1.502 mm


 

 


Crankshaft main bearing insert selection:
Crankcase Main Bearing Bore Diameter Marking Crankshaft Main Journal Diameter Marking Bearing Insert*
Size Color Part Number Journal Nos.
О   Brown 92028-1717 1, 3, 5
92028-1720 2, 4
None   Colorless 92028-1716 1.3. 5
О None 92028-1719 2.4
None None Blue 92028-1715 1, 3. 5
92028-1718 2.4

'The bearing inserts for Nos. 2 and 4 journals have an oil groove, respectively.


Item Standard Service Limit
Transmission:    
Shift fork ear thickness 5.9 - 6.0 mm 5.8 mm
Gear shift fork groove width 6.05 - 6.15 mm 6.25 mm
Shift fork guide pin diameter 7.9 - 8.0 mm 8.1 mm
Shift drum groove width 8.05 - 8.20 mm 8.3 mm

 

Special Tools - Outside Circlip Pliers: 57001-144 Bearing Driver Set 57001-1129 Inside Circlip Pliers: 57001-143

Sealant - Kawasaki Bond (Silicone Sealant): 56019-120


Crankcase Splitting

Crankcase Splitting

• Remove the engine (see Engine Removal/Installation chapter). •Set the engine on a clean surface and hold the engine steady while

parts are being removed.

• Remove:

Clutch (see Clutch chapter) Alternator Chain (see Alternator Chain Removal) Oil Pump (see Engine Lubrication System chapter) Pickup Coil (see Electrical System chapter) *lf the crankshaft is to be removed, remove the pistons (see Engine Top End chapter).

*lf the alternator shaft is to be removed, remove the following. Alternator

Alternator Coupling (see Alternator Shaft, Starter Clutch Removal)

• Remove the upper crankcase bolts. О First loosen the 6 mm bolts.

6 mm Bolts [A] 8 mm Bolts [B]

• Remove the lower crankcase bolts. О First loosen the 6 mm bolts. 6 mm Bolts [A]

8 mm Bolt [B]

9 mm Bolts [C]

•Tap lightly around the crankcase mating surface with a plastic mallet, and split the crankcase. Take care not to damage the crankcase.

Crankcase Assembly


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