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10.CRANKCASE/CRANKSHAFT/TRANS-
MISSION SYSTEM/STARTER SPINDLE Pulsar CK 125
SERVICE INFORMATION ..................... 10-1 STARTER SPINDLE ..............................10- 6
TROUBLESHOOTING ............................ 10-2 CRANKSHAFT.......................................10- 8
CRANKCASE REMOVAL...................... 10-3 CRANKCASE INSTALLATION ...........10-10
TRANSMISSION SYSTEM ....................... 10-3
SERVICE INFORMATION
GENERAL INSTRUCTIONS
· During crankcase separation, do not separate the crankcase halves with an iron hammer to avoid
crankcase deformation or damage.
· After separation, be careful not to damage the right and left crankcase mating surfaces to avoid
oil leakage.
· Replace the gasket with a new one during reassembly of the crankcase halves.
· After transmission system disassembly, make sure that the gear shifting operation is normal
before reassembly of the remaining parts.
· Apply engine oil to the transmission system and crankshaft before reassembly.
SPECIFICATIONS
Item Standard (mm) Service Limit (mm)
Transmission Claw thickness 4.935.0 4.43
fork Shaft hole I.D. 1212.018 12.058
Transmission fork shaft O.D. 11.97611.994 11.936
Transmission Left 12.96612.984 12.926
drum O.D. Right 20.95920.98 20.919
Main shaft starter gear 20.0220.041 20.081
Main shaft 4th gear 2020.021 20.061
Main shaft 5th gear 20.0220.041 20.061
Gear I.D. Countershaft starter idle 20.0220.041 20.081
Countershaft 1st gear 19.5219.541 19.581
Countershaft 2nd gear 2525.021 25.061
Countershaft 3rd gear 2020.021 20.061
Transmission
gear Left crankcase side 14.97814.989 14.938
Main Shaft
O.D. Starter gear 19.95919.98 19.919
4th/5th gear 19.95919.98 19.919
Right crankcase 14.96614.984 14.926
Left crankcase 21.95921.98 21.919
Countershaft
O.D. 1st gear 14.95914.984 14.919
2nd gear 24.95924.98 24.919
3rd gear 19.95919.98 19.919
Connecting rod big end side clearance 0.050.3 0.8
Connecting rod big end radial clearance 00.08 0.05
Crankshaft
Runout 0.03 0.1
10-1