new pulsar 125 Workshop-manual : Page 90

          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