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11. CRANKCASE/CRANKSHAFT AGILITY 50

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11. CRANKCASE/CRANKSHAFT AGILITY 50

SERVICE INFORMATION.......................11-1 CRANKSHAFT....................................... 11-3
TROUBLESHOOTING .............................11-1 CRANKCASE ASSEMBLY................... 11-4
CRANKCASE SEPARATION ..................11-2



SERVICE INFORMATION
GENERAL INSTRUCTIONS
This section covers crankcase separation to service the crankshaft. The engine must be removed
for this operation.
The following parts must be removed before separating the crankcase.
-Cylinder head ( Section 7)
-Cylinder/piston ( Section 8)
-Drive and driven pulleys ( Section 9)
-A.C. generator ( Section 14)
-Carburetor/air cleaner ( Section 5)
-Rear wheel/rear shock absorber ( Section 13)
-Starter motor ( Section 16)
-Oil pump ( Section 4)


SPECIFICATIONS
Item Standard (mm) Service Limit (mm)
Connecting rod big end side clearance 0.100.35 0.55
Crankshaft Connecting rod big end radial clearance 0-0.008 0.05
Runout 0.10


TORQUE VALUES
Crankcase bolt 0.8~1.2kgf-m
Cam chain tensioner slipper bolt 0.8~1.2kgf-m




TROUBLESHOOTING
Excessive engine noise
Excessive bearing play
Excessive crankpin bearing play




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11. CRANKCASE/CRANKSHAFT AGILITY 50

CRANKCASE SEPARATION
Remove the cam chain tensioner slipper bolt
and cam chain tensioner slipper.




Cam Chain Tensioner Slipper Bolt

Crankcase Bolt
Remove the crankcase attaching bolt.
Separate the left and right crankcase halves.

Do not damage the crankcase gasket
surface.
Never use a driver to pry the crankcase
mating surfaces apart.




Remove the gasket and dowel pins.




Dowel Pins
Cam Chain
Remove the crankshaft from the left
crankcase.
Remove the cam chain.




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11. CRANKCASE/CRANKSHAFT AGILITY 50

Clean off all gasket material from the
crankcase mating surfaces.

Avoid damaging the crankcase mating
surfaces.




Oil Seal
Remove the oil seal from the left crankcase.




Oil Seal
Remove the oil seal from the right crankcase.




CRANKSHAFT
Measure the connecting rod big end side
clearance.
Service Limit: 0.55mm replace if over




Connecting Rod Big End
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11. CRANKCASE/CRANKSHAFT AGILITY 50
Measuring Location
Measure the connecting rod big end radial
clearance at two points at right angels to the
shaft.
Service Limit: 0.05mm replace if over




Measure the crankshaft runout.
Service Limit: 0.10mm replace if over




Crankshaft Bearings
Turn the crankshaft bearings and check for
excessive play.
If they do not turn smoothly, quietly or if they
fit loosely in the crankshaft, replace the
crankshaft as a set.




Driver Handle A
CRANKCASE ASSEMBLY
Install new oil seals into the right and left
crankcase .




Outer Driver
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11. CRANKCASE/CRANKSHAFT AGILITY 50
Driver Handle A




Outer Driver
Cam Chain
Install the cam chain into the left crankcase.
Install the crankshaft into the left crankcase.

When installing the cam chain, be
careful not to damage the oil seal.




Gasket
Install the dowel pins and a new gasket onto
the left crankcase.

Place the right crankcase over the
crankshaft and onto the left crankcase.




Dowel Pins
Crankcase Bolt
Tighten the crankcase attaching bolt.
Torque: 0.8~1.2kgf-m




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11. CRANKCASE/CRANKSHAFT AGILITY 50
O-ring
Install the cam chain tensioner slipper.
Install a new O-ring onto the cam chain
tensioner slipper bolt.
Apply engine oil to the O-ring and tighten the
bolt.
Torque: 0.8~1.2kgf-m

Be sure to install the O-ring into the
groove.



Cam Chain Tensioner Slipper Bolt




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