13 13 CRANKCASE/CRANKSHAFT SCHEMATIC DRAWING (XCITING 500) ----------------------------- 13-1 SCHEMATIC DRAWING (XCITING 250) ----------------------------- 13-2 SERVICE INFORMATION------------------------------------------------ 13-3 TROUBLESHOOTING----------------------------------------------------- 13-4 CAM CHAIN/CAM CHAIN GUIDE ------------------------------------- 13-5 CRANKCASE---------------------------------------------------------------- 13-6 CRANKCASE ASSEMBLY (XCITING 500)--------------------------- 13-16 CRANKCASE ASSEMBLY (XCITING 250)--------------------------- 13-18 13-0
SCHEMATIC DRAWING (XCITING 500) 13-1
SCHEMATIC DRAWING (XCITING 250) 13-2
SERVICE INFORMATION GENERAL INSTRUCTIONS This section covers crankcase separation to service the crankshaft and balancer. The engine must be removed for this operation. When separating the crankcase, never use a driver to pry the crankcase mating surfaces apart forcedly to prevent damaging the mating surfaces. When installing the crankcase, do not use an iron hammer to tap it. The following parts must be removed before separating the crankcase. Cylinder head (section 8) Cylinder/piston (section 9) Drive and driven pulley (section 10) A.C. generator/starter clutch (section 12) Starter motor (section 19) Oil pump (section 4) SPECIFICATIONS (XCITING 500) Unit: mm (in) Item Standard Service Limit Main bearing oil clearance 0.025 (0.001)~0.041 (0.0016) 0.7 (0.003) Crankshaft Connecting rod big end side clearance 0.05 (0.002)~0.5 (0.02) 0.8 (0.031) Runout 0.06 (0.002) SPECIFICATIONS (XCITING 250) Crankshaft Unit: mm (in) Item Standard Service Connecting rod big end side clearance 0.15~0.35 (0.006~0.014) 0.6 (0.024) Connecting rod big end radial clearance 0.004~0.008 (0.00016~0.0032) 0.05 (0.002) Runout 0.1 (0.004) 13-3
TORQUE VALUES (XCITING 500) Crankcase bolt 12 N m (1.2 kgf m, 9 lbf ft) Cam chain guide bolt 20 N m (2 kgf m, 15 lbf ft) Oil pipe bolt 43 N m (4.3 kgf m, 31 lbf ft) TORQUE VALUES (XCITING 250) Crankcase bolt 12 N m (1.2 kgf m, 9 lbf ft) Cam chain guide bolt 10 N m (1 kgf m, 10 lbf ft) SPECIAL TOOLS Bearing puller Oil seal & bearing driver E037 E014 TROUBLESHOOTING Excessive engine noise Worn connecting to small end Worn or damaged crankshaft bearings 13-4
CAM CHAIN/CAM CHAIN GUIDE REMOVAL (XCITING 500) Remove the starter driven gear (page 12-5). Remove the cylinder (page 9-4). Remove the cam chain from the right crankcase. Cam Chain Cam Chain Guides Remove the bolts and cam chain guides. Bolts REMOVAL (XCITING 250) Remove the cam chain guide bolt. Remove the cam chain guide and cam chain. Cam Chain Guide Bolt Cam Chain 13-5
INSPECTION Cam chain guide Inspect the cam chain slipper surface of the cam chain guide for wear or damage. Slipper Surface Cam chain Inspect the cam chain for cracks or stiff. CRANKCASE SEPARATION (XCITING 500) Remove the parts required for crankcase separation (page 13-3). Bolts Remove the twelve bolts from left crankcase. Loosen the bolts in a crisscross pattern in several steps. 13-6
Remove the bolt from right crankcase. Bolt Place the crankcase assembly with the left side down and separate the right crankcase from the left crankcase. Separate the right crankcase from the left crankcase while tapping them at several locations with a soft hammer. Remove the dowel pins and O-ring. Remove the oil collar and O-rings from the left crankcase. Clean of the sealant from the left and right crankcase mating surfaces. Dowel Pins Oil Collar/O-rings Dowel Pin/O-ring Remove the washer from the crankshaft. Remove the balancer shaft from the left crankcase. Always replace the crankshaft and balancer shaft in pairs Washer 13-7
Remove the crankshaft from the left crankcase. Always replace the crankshaft and balancer shaft in pairs Crankshaft SEPARATION (XCITING 250) Place the crankcase with the left crankcase down and remove the right crankcase from the left crankcase. Never use a driver to pry the crankcase mating surfaces apart. Bolts Remove the gasket and dowel pins. Gasket Dowel Pins 13-8
Remove the crankshaft from the left crankcase. Crankshaft Left Crankcase RIGHT CRANKCASE DISASSEMBLY (XCITING 500) Remove the two bolts, outer washer, oil pipe and inner washers. Bolts/Outer Washer Oil Pipe/Inner Washers RIGHT CRANKCASE ASSEMBLY Install the inner washers onto the right crankcase. Inner Washers 13-9
Install the oil pipe with the thick side face upward. Thick Side Oil Pipe Install the outer washers and two bolts. Tighten the two bolts to the specified torque. Bolts/Outer Washer Torque: 43 N m (4.3 kgf m, 31 lbf ft) 13-10
CRANKSHAFT/CRANKCASE SELECTION (XCITING 500) Crankcase and crankshaft are select fitted. Main Journal Bearing I.D. Color Code Record the main journal O.D. code ( or ) Record the main journal bearing I.D. color code (green, brown or yellow). Record the right or left crankcase main journal I.D. code (A or B). If the crankcase and/or crankshaft are replaced, select them with the following fitting table. Main Journal O.D. Code The U mark in the table indicates that mating is possible in the crossed code. Main journal O.D. code Main journal bearing I.D. color code /Crankcase main journal I.D. code Green/A Green/B Brown/A Yellow/B U U U U Always replace the crankcase in pairs. Crankcase Main Journal I.D. Code 13-11
MAIN BEARING INSPECTION (XCITING 500) Inspect the bearing inserts for unusual wear, damage or peeling and replace the crankcase if necessary. Main bearing oil clearance Clean off any oil from the main bearing inserts and crankshaft journals. Measure and record the crankshaft main journal O.D.. Measure and record the main bearing I.D.. Calculate the oil clearance by subtracting the journal O.D. from bearing I.D.. Bearing Standard: 0.025 0.041 mm (0.001 0.0016 in) Service limit: 0.07 mm (0.003 in) Replace the crankcase if the service limit is exceeded. Select the replacement crankcase (page 13-11). Runout Side Clearance Runout CRANKSHAFT INSPECTION (XCITING 500) Measure the connecting rod big end side clearance. Service limit: 0.8 mm (0.031 in) Measure the crankshaft runout. Service limit: 0.06 mm (0.002 in) Journals CRANKSHAFT INSPECTION (XCITING 250) Measure the crankshaft runout. Service Limit: 0.1 mm (0.004 in) 13-12
Measure the connecting rod big end side clearance. Service Limit: 0.6 mm (0.024 in) Measure the connecting rod small end I.D. Service Limit: 17.06 mm (0.6824 in) BALANCER SHAFT INSPECTION (XCITING 500) Inspect the balance shaft gear teeth. Burrs/chips/roughness/wear Replace. Balancer Shaft 13-13
BALANCER SHAFT BEARING REPLACMENT (XCITING 500) Remove the crankshaft and balancer shaft (page 13-7). Turn the inner race of each bearing with your finger. The bearings should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the crankcase. Replace the bearings if the races does not turn smoothly and quietly, or if they fit loosely in the crankcase. Remove the balancer shaft bearing from the left crankcase using the special tool. Bearing Puller Special tool: Bearing puller E037 Bearing Remove the bearing snap ring from right crankcase. Snap Ring 13-14
Remove the balancer shaft bearing from the right crankcase. Bearing Install the snap ring into the right crankcase. Snap Ring Oil Seal & Bearing Driver Install the new bearings to the right and left crankcase using special tool. Special tool: Oil seal & bearing driver E014 Bearing 13-15
CRANKCASE ASSEMBLY (XCITING 500) Install the crankshaft to the left crankcase. Crankshaft Align Balancer Shaft Install the balancer shaft to align the punch mark with the O mark on the crankshaft. Washer Install the washer onto the crankshaft. 13-16
Install the oil collar and O-rings Dowel Pins Clean the right and left crankcase mating surface thoroughly, being careful not to damage them. Install the dowel pins and O-ring. Oil Collar/O-rings Dowel Pin/O-ring Apply a light but through coating of sealant (Threebond 1215 or equivalent) to all crankcase mating surfaces except the oil passage area. Bolt Install the right crankcase over the left crankcase. Install and turn in the right crankcase bolt but do not tighten it. Install and tighten the left crankcase bolts in a crisscross pattern in 2 3 steps to the specified torque. Bolts Torque: 12 N m (1.2 kgf m, 9 lbf ft) Tighten the right crankcase bolt to the specified torque. Torque: 12 N m (1.2 kgf m, 9 lbf ft) Make sure that the crankshaft turns smoothly. 13-17
Install the cam chain guides to the right crankcase and tighten the bolts to the specified torque. Cam Chain Guides Torque: 20 N m (2 kgf m, 15 lbf ft) Install the cam chain to right crankcase. Cam Chain CRANKCASE ASSEMBLY (XCITING 250) Clean off all gasket material from the crankcase mating surfaces. Avoid damaging the crankcase mating surfaces. Install a new oil seal into the left crankcase. Oil Seal Left Crankcase 13-18
Place the left crankcase down and install the crankshaft into the left crankcase. Avoid damaging the oil seal. Apply grease to the lip of the oil seal. Install the two dowel pins and a new gasket. Gasket Dowel Pins Place the right crankcase over the crankshaft and onto the left crankcase. Install the right crankcase squarely and do not tap it with an iron or plastic hammer. Bolts Install and tighten the right and left crankcase attaching bolts. Torque: 12 N m (1.2 kgf m, 9 lbf ft) 13-19
Install the cam chain. Install the cam chain tensioner slipper. Install and tighten the cam chain tensioner slipper bolt. Torque: 10 N m (1 kgf m, 10 lbf ft) Cam Chain Tensioner Slipper Bolt 13-20