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10. CRANKCASE/CRANKSHAFT/KICK
STARTER/TRANSMISSION K-PIPE 125
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 4.45
fork Shaft hole I.D. 34.0234.05 34.05
Transmission fork shaft O.D. 33.9033.96 33.90
Transmission Left 1313.02 13
drum O.D. Right 16.1016.12 16.04
Main shaft 2nd gear 17.017.018 17.058
Main shaft 3rd gear 17.017.018 17.058
Main shaft 4th gear 17.01617.034 17.074
Gear I.D. Countershaft 1st gear 23.02023.041 23.081
Countershaft 2nd gear 20.020.021 22.061
Countershaft 3rd gear 23.02023.041 23.081
Countershaft 4th gear 20.020.021 22.061
Transmission
Left crankcase side 11.97811.9899 11.938
gear Main Shaft
Starter gear 25.3025.50 25.20
O.D.
2nd /3rd/4th gear 16.96616.984 16.926
Right crankcase 11.97811.989 11.938
Left crankcase 16.97816.989 16.938
Countershaft
1st gear 16.97816.989 16.938
O.D.
2nd gear 18.8019.0 18.760
3rd/4th gear 19.95919.98 19.919
Connecting rod big end side clearance 0.050.3 0.8
Crankshaft Connecting rod big end radial clearance 00.05 0.05
Runout 0.03 0.1
10-2