20
2.0
10
1.0
12
1.2
20
2.0
27
2.8
44
4.5

ft·lb
87 in·lb
18
←
61 in·lb
52 in·lb
87 in·lb
106 in·lb
15
89 in·lb
106 in·lb
15
20
32

14. Do not apply any grease or oil.
EO: Apply engine oil.
G: Apply grease.
L: Apply a non-permanent locking agent.
LG: Apply liquid gasket.
M: Apply molybdenum disulfide grease.
MO: Apply molybdenum disulfide oil solution.
(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1)
R: Replacement Parts
S: Follow the specified tightening sequence.

Remarks

L
MO
L
L
L
L
L
S
S
S
MO, S

9-4 CRANKSHAFT/TRANSMISSION
Exploded View

CRANKSHAFT/TRANSMISSION 9-5
Exploded View
No.
1
2
3
4
5
6
7

Fastener
Gear Positioning Lever Bolt
Shift Drum Bearing Holder Bolts
Shift Drum Cam Holder Bolt
Shift Shaft Return Spring Pin
Shift Pedal Mounting Bolt
Shift Lever Clamp Bolt
Gear Position Sensor Bolt

N·m
12
12
12
39
25
9.8
10

Torque
kgf·m
1.2
1.2
1.2
4.0
2.5
1.0
1.0

ft·lb
106 in·lb
106 in·lb
106 in·lb
29
18
87 in·lb
89 in·lb

EO: Apply engine oil.
G: Apply grease.
MO: Apply molybdenum disulfide oil solution.
(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1)
L: Apply a non-permanent locking agent.
Lh: Left-hand Threads
R: Replacement Parts

Remarks

L
L
L
G
L
L

9-6 CRANKSHAFT/TRANSMISSION
Specifications
Item
Crankcase, Crankshaft, Connecting
Rods
Connecting Rod Bend
–––
Connecting Rod Twist
Connecting Rod Big End Side
Clearance
Connecting Rod Big End Bearing
Insert/Crankpin Clearance
Crankpin Diameter:
Marking:
None

○
Connecting Rod Big End Inside
Diameter:
Marking:
None

○
Connecting Rod Big End Bearing
Insert Thickness:
Brown
Black
Blue
Connecting Rod Bolt Stretch:
New Connecting Rod (Use the
bolts attached to new connecting
rod.)
Used Connecting Rod (Replace
the bolts with new ones.)
Crankshaft Side Clearance
Crankshaft #3 Main Journal Width
Crankshaft Runout
Crankshaft Main Bearing
Insert/Journal Clearance
Crankshaft Main Journal Diameter:
Marking:
None
1

Standard

Service Limit

TIR 0.2/100mm
(0.008/3.94 in.)
–––
TIR 0.2/100mm
(0.008/3.94 in.)
0.13  0.38 mm (0.0051  0.0150 in.)
0.6 mm (0.02
in.)
0.10 mm
0.030  0.060 mm (0.0012  0.0024 in.)
(0.0039 in.)
34.47 mm
34.484  34.500 mm (1.3576  1.3583 in.)
(1.357 in.)
34.484  34.492 mm (1.3576  1.35795
in.)
34.493  34.500 mm (1.35799  1.3583
in.)
37.500  37.516 mm (1.4764  1.4770 in.)

– – –

37.500  37.508 mm (1.4764  1.47669
in.)
37.509  37.516 mm (1.47673  1.4770
in.)

– – –

1.478  1.483 mm (0.05819  0.05839 in.)
1.483  1.488 mm (0.05839  0.05858 in.)
1.488  1.493 mm (0.05858  0.05878 in.)

– – –
– – –
– – –

(Usable Range) 0.20  0.32 mm (0.0079
 0.0126 in.)

– – –

(Usable Range) 0.24  0.36 mm (0.0094
 0.0142 in.)
0.09  0.19 mm (0.0035  0.0075 in.)

– – –

34.984  34.992 mm (1.3773  1.3776 in.)
34.993  35.000 mm (1.3777  1.3780 in.)

– – –
– – –

– – –
– – –

– – –

0.39 mm (0.015
in.)
23.49  23.54 mm (0.9248  0.9268 in.)
– – –
TIR 0.02 mm (0.0008 in.) or less
TIR 0.05 mm
(0.0020 in.)
0.06 mm
0.010  0.034 mm (0.0004  0.0013 in.)
(0.0024 in.)
34.96 mm
34.984  35.000 mm (1.3773  1.3780 in.)
(1.376 in.)

CRANKSHAFT/TRANSMISSION 9-7
Specifications
Item
Crankcase Main Bearing Inside
Diameter:
Marking:
None

Standard
38.000  38.016 mm (1.4961  1.4967 in.)

○
Crankshaft Main Bearing Insert
Thickness:
Brown
Black
Blue
Transmission
Shift Fork Ear Thickness

Service Limit
– – –

38.000  38.008 mm (1.4961  1.49637
in.)
38.009  38.016 mm (1.49641  1.4967
in.)

– – –

1.491  1.495 mm (0.05870  0.05886 in.)
1.495  1.499 mm (0.05886  0.05902 in.)
1.499  1.503 mm (0.05902  0.05917 in.)

– – –
– – –
– – –

– – –

5.9  6.0 mm (0.232  0.236 in.)

Shifter Groove Width

6.05  6.15 mm (0.238  0.242 in.)

Shift Fork Guide Pin Diameter

6.9  7.0 mm (0.272  0.276 in.)

Shift Drum Groove Width

7.05  7.20 mm (0.278  0.283 in.)

5.8 mm (0.228
in.)
6.3 mm (0.25
in.)
6.8 mm (0.268
in.)
7.3 mm (0.29
in.)

Connecting Rod Big End Bearing Insert Selection
Bearing Insert

Con-rod Big End
Inside Diameter
Marking

Crankpin Diameter
Marking

Size Color

Part Number

None

○

Brown

92139-0124

None

None

○
○

○

Black

92139-0123

None

Blue

92139-0122

Crankshaft Main Bearing Insert Selection
Crankcase Main Crankshaft Main
Bearing Inside Journal Diameter
Diameter Marking
Marking

○

1

None

1

○

None

None

None

Bearing Insert*
Size Color
Brown
Black
Blue

Part Number

Journal Nos.

92139-0034
92139-0219
92139-0033

2, 4
1, 3, 5
2, 4

92139-0218

1, 3, 5

92139-0032
92139-0217

2, 4
1, 3, 5

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

9-8 CRANKSHAFT/TRANSMISSION
Special Tools and Sealants
Bearing Puller:
57001-135

Bearing Driver Set:
57001-1129

Outside Circlip Pliers:
57001-144

Flywheel Holder:
57001-1313

Bearing Puller Adapter:
57001-317

Liquid Gasket, TB1216B:
92104-1064

Bearing Driver,
57001-382

Liquid Gasket, TB1207B:
92104-2068

32:

CRANKSHAFT/TRANSMISSION 9-9
Crankcase Splitting
Crankcase Splitting

the engine (see Engine Removal in the Engine
• Remove
Removal/Installation chapter).
the engine on a clean surface and hold the engine
• Set
steady while parts are being removed.
MY model, remove the oil cooler (see Oil Cooler Re• For
moval in the Engine lubrication System chapter)
other than MY model, remove the oil passage cover.
• For
Remove:
• Cylinder (see Cylinder Removal in the Engine Top End
chapter)
Clutch (see Clutch Removal in the Clutch chapter)
External Shift Mechanism (see External Shift Mechanism Removal)
Starter Motor (see Starter Motor Removal in the Electrical System chapter)
Oil Pump (see Oil Pump Removal in the Engine Lubrication System chapter)
Alternator Rotor (see Alternator Rotor Removal in the
Electrical System chapter)
Oil Pipe (see Oil Pipe Removal in the Engine Lubrication
System chapter)
Oil Screen (see Oil Screen Removal in the Engine Lubrication System chapter)
If the crankshaft is to be removed, remove the pistons
(see Piston Removal in the Engine Top End chapter).
the balancer shaft clamp bolt [A].
• Loosen
Remove:
• Balancer Shaft Clamp Lever Bolt [B]
Balancer Shaft Clamp Lever [C]

the upper crankcase bolts, following the speci• Remove
fied sequence.

○Firstly, loosen the M6 bolts [A].
○Secondly, loosen the M7 bolts [B].
○Lastly, loosen the M8 bolts [C].

9-10 CRANKSHAFT/TRANSMISSION
Crankcase Splitting
the lower crankcase bolts, following the specified
• Remove
sequence.

○Firstly, loosen the M7 bolts [A].
○Lastly, loosen the M9 bolts as shown sequence [1  10].

lightly around the crankcase mating surface with a
• Tap
plastic mallet, and split the crankcase.

○Take care not to damage the crankcase.

Crankcase Assembly
NOTICE
The upper and lower crankcase halves are machined at the factory in the assembled state, so the
crankcase halves must be replaced as a set.
a high flash-point solvent, clean off the mating sur• With
faces of the crankcase halves and wipe dry.
compressed air, blow out the oil passages in the
• Using
crankcase halves.
a high flash-point solvent, clean off any oil or dirt
• Using
that may be on the liquid gasket coating area. Dry them
with a clean cloth.
Apply liquid gasket to the breather plate mating surface
[A] 1 mm (0.04 in.) or more thick, and then install the
breather plate.
○Apply liquid gasket start from the corner area [B] as
shown.

•

Sealant - Liquid Gasket, TB1207B: 92104-2068

NOTE

○Make the application finish within 7 minutes when the
liquid gasket to the mating surface of the breather plate
is applied.
○Moreover fit the plate and tighten the bolts just after
application of the liquid gasket.

CRANKSHAFT/TRANSMISSION 9-11
Crankcase Splitting
a non-permanent locking agent to the threads of
• Apply
the breather plate bolts [A] and tighten them.
Torque - Breather Plate Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)

the breather side plate [A] so that the plate hole [B]
• Install
fit the projection [C] of the upper crankcase.
a non-permanent locking agent to the threads of
• Apply
the breather side plate bolt [D] and tighten it.
Torque - Breather Side Plate Bolt: 5.9 N·m (0.60 kgf·m, 52
in·lb)

the fitting [A] in the upper crankcase [B] until it is
• Press
bottomed.
Special Tool - Bearing Driver Set: 57001-1129

the plug [C] in the upper crankcase so that the plug
• Press
is deeper than crankcase surface.
Special Tool - Bearing Driver Set: 57001-1129

the new needle bearing [A] for the shift shaft so that
• Press
its marked side faces outside and its surface [B] is flush
with the end of the hole.
Special Tool - Bearing Driver Set: 57001-1129

the new oil seal [C] so that its surface [D] is flush
• Install
with the end of the hole.
Special Tool - Bearing Driver Set: 57001-1129

• Apply grease to the oil seal lips.
a non-permanent locking agent to the oil passage
• Apply
plugs [A], and tighten them.
Torque - Oil Passage Plugs: 20 N·m (2.0 kgf·m, 15 ft·lb)

the oil passage plug [B] in the lower crankcase, and
• Install
tighten it.
Torque - Oil Passage Plug: 10 N·m (1.0 kgf·m, 89 in·lb)

9-12 CRANKSHAFT/TRANSMISSION
Crankcase Splitting

• Install:
Crankshaft (see Crankshaft Installation)
Connecting Rods (see Connecting Rod Installation)
Balancer (see Balancer Installation)
Transmission Shafts (see Transmission Shaft Installation)
Dowel Pins [A]
Shift Drum (see Shift Drum and Fork Installation)
Shift Forks and Shift Rods (see Shift Drum and Fork Installation)
Before fitting the lower case on the upper case, check the
following.
○Be sure to hang the camshaft chain on the crankshaft.
○Check to see that the shift drum and transmission gears
are in the neutral position.

•

a high flash-point solvent, clean off any oil or dirt
• Using
that may be on the liquid gasket coating area. Dry them

•

with a clean cloth.
Apply liquid gasket [A] to the mating surface of the lower
crankcase half.
Sealant - Liquid Gasket, TB1216B: 92104-1064

NOTE