7-10 ENGINE BOTTOM END/TRANSMISSION
Crankshaft, Connecting Rod
Crankshaft Removal
•
Split the crankcase (see Crankcase Splitting).
•
Remove the transmission shafts (see Transmission Shaft
Removal).
•
Using a press, remove the crankshaft from the right
crankcase.
○
If the bearings stay on the crankshaft when splitting the
crankcase or removing the crankshaft from the right
crankcase, remove the bearings from the crankshaft with
a bearing puller [A] and adapter [B].
Special Tools - Bearing Puller: 57001-158
Bearing Puller Adapter: 57001-136
Crankshaft Installation
•
When installing the crankshaft bearings [B], apply high
temperature grease to the outer sides of the bearings,
and then press them into the crankcase using the bearing
driver [A] until the bearing bottoms against the step.
○
Position the crankcase half so that the main bearing hous-
ing is seated on a suitable press fixture.
○
Install the crankshaft bearing so that the sealed side in (to
the oil seal [C] side).
Special Tool - Bearing Driver Set: 57001-1129
•
Insert the crankshaft jig [A] between the crankshaft fly-
wheels opposite the connecting rod big end to protect
flywheel alignment as shown, and using a suitable tool
[B] on the left crankcase to press around the hole for the
crankshaft.
○
When pressing, position the jig in the crankcase opening
so the jig does not hit the crankcase.
Special Tool - Crankshaft Jig: 57001-1439
•
Apply 2-stroke oil to the connecting rod big end bearing.
Crankshaft Disassembly
Since assembly of the crankshaft demands exacting tol-
erances, the disassembly and reassembly of the crankshaft
can only be done by a shop having the necessary tools and
equipment.
•
If it should be necessary to disassemble the crankshaft,
use a press to remove the crankpin.
Crankshaft Assembly
Since the assembly of the crankshaft demands exacting
tolerances, the disassembly and reassembly of the crank-
shaft can only be done by a shop having the necessary tools
and equipment.
•
Reassemble the crankshaft according to the standard tol-
erances in Specifications.
○
Connecting rod bend, twist
○
Connecting rod big end radial clearance.
○
Cold-fitting tolerance between crankpin and flywheels.
○
Side clearance between the connecting rod big end and
one of flywheels.
○
Crankshaft runout.
