Honda CRF450R 2009 Service Manual page 345

CRANKCASE/CRANKSHAFTfTRANSMISSION/BALANCER
Measure the 1.0 . of each gear.
SERVICE LIMITS:
M4 : 28.05 mm (1 .104 in)
MS, C3: 28.07
mm
(1 .105 In)
C2:
30.07 mm (1 .184
In)
BUSHING
Check the bushings for damage or excessive wear.
Measure the 0 .0 . of each bushing.
SERVICE LIMITS:
M4, MS, C3: 27.95 mm (1 .100 in)
C2: 29.95 mm (1 .179 in)
Calculate the gear-la-bushing clearance.
SERVICE LIMITS:
M4: 0.11 mm (0 .004 In)
MS, C2, C3: 0.12
mm
(0.005
in)
Measure the 1.0. of each bushing.
SERVICE LIMITS :
M5: 25.04 mm (0.986 in)
C2 : 27.04 mm (1.065 in)
C3 :
25.02 mm (0.985
In)
MAINSHAFT/COUNTERSHAFT
-0-
Check the spline grooves and sliding surfaces for , - - - - - - - - - - - - - -- - - ,
damage or abnormal wear.
Measure the
0 .0 .
of the mainshaft and countershaft at
the bushing sliding areas.
SERVICE LIMITS :
Mainshaft:
(at MS bushing) : 24.94 mm (0.982 In)
Countershaft:
(at C2 bushing): 26.94 mm (1 .061 in)
(at C3 bushing): 24.94 mm (0.982 in)
Calculate the bUShing-to-shaft clearance.
SERVICE LIMITS :
MS, C2: 0.12 mm (0.005 In)
C3 : 0.08
mm
(0.003 In)
SHIFT FORK
Check the shift forks for abnormal wear or deformation .
Measure the shift fork I. D. and claw thickness .
SERVICE LIMITS:
1 .0 .: Center: 11 .04 mm (0.435 in)
Right and left: 12.07 mm (0.475 in)
Claw thickness : 4.8 mm (0.19 in)
M5
C2 C3
'09 shown:
13·17