Blue

92139-0122

Bearing Insert

the new inserts in the connecting rod and check
• Install
insert/crankpin clearance with the plastigage.

Crankshaft Side Clearance Inspection

a thickness gauge [A] between the crankcase main
• Insert
bearing and the crank web at the #3 journal to determine
clearance.
If the clearance exceeds the service limit, replace the
crankcase halves as a set.

NOTE

○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.
Crankshaft Side Clearance
Standard:
0.09  0.19 mm (0.0035  0.0075 in.)
Service Limit: 0.39 mm (0.0154 in.)

9-24 CRANKSHAFT/TRANSMISSION
Crankshaft and Connecting Rods
Crankshaft Runout Inspection

the crankshaft runout.
• Measure
If the measurement exceeds the service limit, replace the
crankshaft.
Crankshaft Runout
Standard:
TIR 0.02 mm (0.0008 in.) or less
Service Limit: TIR 0.05 mm (0.0020 in.)

Crankshaft Main Bearing Insert/Journal Wear
Inspection

the crankcase (see Crankcase Splitting).
• Split
Cut
strips
of plastigage (press gauge) to journal width.
• Place a strip
each journal parallel to the crankshaft
• installed in theoncorrect
position.
the crankcase bolts to the specified torque (see
• Tighten
Crankcase Assembly).

NOTE

○Do not turn the crankshaft during clearance measurement.

○Journal clearance less than 0.025 mm (0.00098 in.) can
not be measured by plastigage [A], however, using genuine parts maintains the minimum standard clearance.
the crankcase again, measure each clearance be• Split
tween the bearing insert and journal [B] using plastigage
(press gauge).
Crankshaft Main Bearing Insert/Journal Clearance
Standard:
0.010  0.034 mm (0.0004  0.0013 in.)
Service Limit: 0.06 mm (0.0024 in.)

If the clearance is within the standard, no bearing replacement is required.
If the clearance is between 0.035 mm (0.0014 in.) and the
service limit (0.06 mm, 0.0024 in.), replace the bearing inserts [A] with inserts painted blue [B]. Check insert/journal
clearance with the plastigage. The clearance may exceed
the standard slightly, but it must not be less than the minimum in order to avoid bearing seizure.
If the clearance exceeds the service limit, measure the
diameter of the crankshaft main journal.

CRANKSHAFT/TRANSMISSION 9-25
Crankshaft and Connecting Rods
Crankshaft Main Journal Diameter
Standard:
34.984  35.000 mm (1.3773  1.3780 in.)
Service Limit: 34.96 mm (1.376 in.)

If any journal has worn past the service limit, replace the
crankshaft with a new one.
If the measured journal diameters [A] are not less than the
service limit, but do not coincide with the original diameter
markings [B] on the crankshaft, make new marks on it.
Crankshaft Main Journal Diameter Marks
None 34.984  34.992 mm (1.3773  1.3776 in.)
1

34.993  35.000 mm (1.3777  1.3780 in.)

□:

Crankshaft Main Journal Diameter Marks, “1” or no
mark.

the main bearing inside diameter, and mark the
• Measure
upper crankcase half in accordance with the inside diam-

•

eter.
Crankcase Main Bearing Inside Diameter Marks: “○” or
no mark.
Tighten the crankcase bolts to the specified torque (see
Crankcase Assembly).

NOTE

○The mark already on the upper crankcase half should
almost coincide with the measurement.
Crankcase Main Bearing Inside Diameter Marks
38.000  38.008 mm (1.4961  1.49637 in.)

○

None

38.009  38.016 mm (1.49641  1.4967 in.)

the proper bearing insert [A] in accordance with the
• Select
combination of the crankcase and crankshaft coding.
Size Color [B]

9-26 CRANKSHAFT/TRANSMISSION
Crankshaft and Connecting Rods
Crankcase Main
Bearing Inside
Diameter Marking

Crankshaft Main
Journal Diameter
Marking

Size Color

○

1

Brown

None

1

○

None

None

None

Bearing Insert*

Black
Blue

Part Number
92139-0034
92139-0219
92139-0033

Journal Nos.
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.
the new inserts in the crankcase halves and check
• Install
insert/journal clearance with the plastigage.

CRANKSHAFT/TRANSMISSION 9-27
Balancer
Balancer Removal

the crankcase (see Crankcase Splitting).
• Split
• Remove:
Oil Seal [A]
Balancer [B]

Balancer Installation

• Check that the rubber dampers [A] are in place as shown.

molybdenum disulfide oil solution to the damper
• Apply
contact portions of the balancer weight [A].
the balancer weight into the gear [B].
•○Install
Align the punch mark [C] of the balancer weight with the
groove [D] of the gear.

molybdenum disulfide oil solution to the needle
• Apply
bearings. Insert the needle bearings.
the washers [A] on both ends of the weight and gear
• Fit
assembly. The projected sides [B] face inward.

the pin [A] as shown.
• Insert
the balancer on the upper crankcase half.
•○Set
Align the punch mark [B] on the balancer gear [C] with the
mark [D] on the balancer drive gear [E] of crankshaft.

9-28 CRANKSHAFT/TRANSMISSION
Balancer
the crankcase (see Crankcase Assembly).
• Assemble
Fill
the
oil
seal
lips with grease.
• Install the new oil
[A] so that its surface is flush with
• the surface of the seal
crankcase.
the balancer shaft clamp lever [B].
• Install
Apply
a
non-permanent locking agent to the threads of
• the balancer
shaft clamp lever bolt [C].
Tighten:
•
Torque - Balancer Shaft Clamp Lever Bolt: 25 N·m (2.5
kgf·m, 18 ft·lb)

the balancer shaft so that its mark [D] faces down• Turn
ward.
that the balancer shaft clamp lever is in contact
• Check
with the oil seal.
• Tighten:
Torque - Balancer Shaft Clamp Bolt [E]: 9.8 N·m (1.0 kgf·m,
87 in·lb)

Balancer Adjustment

the engine and warm it up thoroughly.
• Start
Adjust
the balancer gear backlash with the engine idling.
• The amount
of backlash can be changed by turning the
balancer shaft which has eccentric journals.

○Start the engine and let it idle.
○Loosen the clamp bolt [A] and turn the balancer shaft [B]
clockwise [C] until the balancer gear makes a whining
sound.
○Turn the shaft counterclockwise [D] until the balancer gear
whining sound disappears and tighten the clamp bolt.
Torque - Balancer Shaft Clamp Bolt: 9.8 N·m (1.0 kgf·m, 87
in·lb)

Balancer Damper Inspection

the balancer and disassemble the weight and
• Remove
gear assembly.
inspect the rubber dampers [A].
• Visually
If they appear damaged or deteriorated, replace them.

CRANKSHAFT/TRANSMISSION 9-29
Starter Motor Clutch
Starter Motor Clutch Removal/Installation

• Refer to the Starter Motor Clutch Disassembly/Assembly.
Starter Motor Clutch Disassembly

the alternator rotor (see Alternator Rotor Re• Remove
moval in the Electrical System chapter).
• Hold the alternator rotor with the flywheel holder [A].
Special Tool - Flywheel Holder: 57001-1313

• Remove the starter motor clutch bolts [B].
• Remove:
Starter Motor Clutch Housing [A]
Starter Motor Clutch [B]

Starter Motor Clutch Assembly

the starter motor clutch to the housing so that the
• Install
flange [A] fit to the housing groove [B].
• Hold the alternator rotor with the flywheel holder.
Special Tool - Flywheel Holder: 57001-1313

a non-permanent locking agent to the threads of
• Apply
the starter motor clutch bolts and tighten them.
Torque - Starter Motor Clutch Bolts: 12 N·m (1.2 kgf·m, 106
in·lb)

Starter Motor Clutch Inspection

• Remove:
Alternator Cover (see Alternator Cover Removal in the
•
•

Electrical System chapter)
Starter Idle Gear and Shaft
Turn the starter motor clutch gear [A] by hand. The starter
motor clutch gear should turn clockwise [B] freely, but
should not turn counterclockwise [C].
If the starter motor clutch does not operate as it should or
if it makes noise, go to the next step.
Disassemble the starter motor clutch, and visually inspect
the clutch parts.
If there is any worn or damaged part, replace it.

NOTE

○Examine the starter motor clutch gear as well. Replace
it if it worn or damaged.

9-30 CRANKSHAFT/TRANSMISSION
External Shift Mechanism
Shift Pedal Removal

• Remove:
Shift Lever Bolt [A]

Shift Lever [B]
If the tie-rod is removed from the shift pedal and shift lever,
note the following.
○The following portions have left-hand threads.
Locknut [C] of Shift Lever Side
Ball Joint [D] of Shift Lever
Remove:
Shift Pedal Mounting Bolt [E]
Shift Pedal [F] with Tie-Rod [G]
Washer

•

Shift Pedal Installation

grease to the sliding surface [A] on the shift pedal
• Apply
mounting bolt [B].
• Install:
Washer [C]

•

Tie-Rod [D] and Shift Pedal [E]
Tighten:
Torque - Shift Pedal Mounting Bolt: 25 N·m (2.5 kgf·m, 18
ft·lb)

the punch mark [A] on the shift shaft with the slit [B]
• Align
of the shift lever.
a non-permanent locking agent to the threads of
• Apply
the shift lever bolt [C] and tighten it.

installation, confirm that the shift pedal [A] is posi• After
tioned as shown.
123 mm (4.843 in.) [B]
If the pedal position is different, adjust it as follows.
○To adjust the pedal position, loosen the front locknut [C]
(left-hand threads) and rear locknut [D], and then turn the
tie-rod [E].
○Tighten the locknuts securely.

CRANKSHAFT/TRANSMISSION 9-31
External Shift Mechanism
External Shift Mechanism Removal

• Remove:
Engine Sprocket Cover (see Engine Sprocket Removal
in the Final Drive chapter)
Shift Lever (see Shift Pedal Removal)
Clutch (see Clutch Removal in the Clutch chapter)
Circlip [A]
Washer [B]
Special Tool - Outside Circlip Pliers: 57001-144

• Remove the shift shaft assembly [A].

• Remove:
Gear Positioning Lever Bolt [A]
Gear Positioning Lever [B]
Collar and Spring [C]

External Shift Mechanism Installation
the following parts as shown.
• Assemble
Gear Positioning Lever [A]

Spring [B]
Collar [C]
Gear Positioning Lever Bolt [D]
○Hang the spring end [E] to the gear positioning lever.

prying the gear positioning lever [A], tighten the
• While
gear positioning lever bolt [B].
Torque - Gear Positioning Lever Bolt: 12 N·m (1.2 kgf·m,
106 in·lb)

9-32 CRANKSHAFT/TRANSMISSION
External Shift Mechanism

• Apply grease to the lips of the oil seal [A].

the shift shaft [A] so that the return spring pin [B]
• Install
fits between the spring [C].

the washer [A].
• Install
Replace
the circlip [B] with a new one, and install it.
•
Special Tool - Outside Circlip Pliers: 57001-144

○Fit the circlip into the groove of the shift shaft securely.

• Install the removed parts (see appropriate chapters).

External Shift Mechanism Inspection

the shift shaft [A] for any damage.
• Examine
If the shaft is bent, straighten or replace it.
If the serration [B] are damaged, replace the shaft.
If the springs [C] are damaged in any way, replace them.
If the shift mechanism arm [D] is damaged in any way,
replace the shift shaft.

the return spring pin [A] is not loose.
• Check
If it is loose, unscrew it, apply a non-permanent locking
agent to the threads, and tighten it.
Torque - Shift Shaft Return Spring Pin: 39 N·m (4.0 kgf·m,
29 ft·lb)

CRANKSHAFT/TRANSMISSION 9-33
External Shift Mechanism
the gear positioning lever [A] and its spring for
• Check
breaks or distortion.

•

If the lever or spring are damaged in any way, replace
them.
Visually inspect the shift drum cam [B].
If it is badly worn or shows any damage, replace it.

9-34 CRANKSHAFT/TRANSMISSION
Transmission
Transmission Shaft Removal

the crankcase (see Crankcase Splitting).
• Split
• Remove the drive shaft [A] and output shaft [B].

Transmission Shaft Installation

to see that the set pins [A] and set rings [B] are in
• Check
place.

molybdenum disulfide oil solution to the transmis• Apply
sion gears.
the drive shaft and output shaft into the upper
• Install
crankcase half.
engine oil to the bearings.
•○Apply
The bearing set pins and rings must match properly with
the holes or grooves in the bearing outer races or bearings. When they are properly matched, there is no clearance [A] between the crankcase and the bearing outer
races or bearings.
the crankcase (see Crankcase Assembly).
• Assemble
Replace
the
[A] with a new one.
• Apply greaseoiltoseal
the
oil
• ence of the oil seal. seal lips and the inner circumfersoap and water solution to the outer circumference
• Apply
of the oil seal so that it will go into place smoothly.
in the oil seal into the crankcase so that the surface
• Press
of the oil seal is flush with the surface [B] of the crankcase.

Transmission Shaft Disassembly

the transmission shafts (see Transmission Shaft
• Remove
Removal).
the circlips, and disassemble the transmission
• Remove
shafts.
Special Tool - Outside Circlip Pliers: 57001-144

5th gear [A] on the output shaft has three steel balls
• The
assembled into it for the positive neutral finder mechanism. Remove the 5th gear.
○Set the output shaft in a vertical position holding the 3rd
gear [B].
○Spin the 5th gear quickly [C] and pull it off upward.

CRANKSHAFT/TRANSMISSION 9-35
Transmission
the ball bearing [A] from each shafts and collar
• Remove
[B] from output shaft.
Special Tools - Bearing Puller [C]: 57001-135
Bearing Puller Adapter [D]: 57001-317

• Discard the bearing and collar (output shaft).

Transmission Shaft Assembly

the new ball bearing [A] on the each shaft, using
• Install
the bearing driver.
Spacial Tool - Bearing Driver,

32: 57001-382

the collar [A] on the output shaft, using the bearing
• Install
driver.
Special Tool - Bearing Driver,

32: 57001-382

engine oil to the bushings, ball bearings and shafts.
• Apply
the gear bushings [A] on the shaft with their holes
• Install
[B] aligned.

any circlips removed with new ones.
• Replace
Install
the
[A] so that the opening [B] is aligned
• with a splinecirclips
groove [C].

9-36 CRANKSHAFT/TRANSMISSION
Transmission
drive shaft gears can be recognized by size: the gear
• The
with the smallest diameter is 1st gear, and the largest one

•
•
•
•
•

is 6th gear. Be sure that all parts are put back in the correct sequence and all circlips and washers are properly in
place.