Service Information - Honda TRX450R Service Manual

CRANKCASE/TRANSMtSSION/CRANKSHAFT/BALANCER (After '05)
SERVICE INFORMATION
GENERAL
• The crankcase halves must be separated to service the transmission, crankshaft and oil pump. To service these parts,
the engine must be removed from the frame (page 10-5).
• Be careful not to damage the crankcase mating surfaces when servicing.
SPECIFICATIONS
Unit: mm (in)
ITEM
Shift fork,
shaft
Transmission
Crankshaft
Fork I.D.
Shaft O.D.
Left
Right
Center
Left/right
Center
Fork claw thickness
Gear I.D;
Gear bushing O.D.
Gear bushing I.D.
Mainshaft O.D.
Countershaft O.D.
Runout
M4
M5
C1
C2
C3
M4, M5
C1
C2
C3
M5
C1
C2
C3
atM5
atCi
atC2
atC3
Left
Right
Big end side clearance
Big end radial clearance
STANDARD
12.035 - 12.056 (0.4738 - 0.4746)
12.003 - 12.024 (0.4726 - 0.4734)
11.003 - 11.024 (0.4332 - 0.4340)
11.966 - 11.984 (0.4711 - 0.4718)
10.969 - 10.980 (0.4319 - 0.4323)
4.93-5.00(0.194-0.197)
28.007 - 28.028 (1.1026 - 1.1035)
28.020 - 28.033 (1.1031 - 1.1037)
22.020 - 22.041 (0.8669 - 0.8678)
30.020-30.041 (1.1819-1.1827)
28.020 - 28.041 (1.1031 - 1.1040)
27.959 - 27.980 (1.1007 - 1.1016)
21.959 - 21.980 (0.8645 - 0.8654)
29.959 - 29.980 (1.1795 - 1.1803)
27.959 - 27.980 (1.1007 - 1.1016)
25.020-25.041 (0.9850-0.9859)
19.020-19.041 (0.7488-0.7496)
27.020 - 27.041 (1.0638 - 1.0646)
25.020 - 25.041 (0.9850 - 0.9859)
24.967 - 24.980 (0.9830 - 0.9835)
18.959 - 18.980 (0.7464 - 0.7472)
26.959 - 26.980 (1.0614 - 1.0622)
24.959 - 24.980 (0.9826 - 0.9835)
-
-
0.30-0.75(0.012-0.030)
0.006 - 0.018 (0.0002 - 0.0007)
SERVICE LIMIT
12.07(0.475)
12.04(0.474)
11.04 (0.435)
11.950 (0.4700)
10.969 (0.4319)
4.8 (0.19)
28.05(1.104)
28.06(1.105)
22.07 (0.869)
30.07(1.184)
28.07 (1.105)
27.94(1.100)
21.94 (0.864)
29.94(1.179)
27.94(1.100)
25.06 (0.987)
19.06 (0.750)
27.06(1.065)
25.06 (0.987)
24.95 (0.982)
18.94(0.746)
26.94(1.061)
24.94 (0.982)
0.05 (0.002)
0.03(0.001)
0.75 (0.030)
0.05 (0.002)
TORQUE VALUE
Balancer shaft lock nut
Cam chain tensioner bolt
Primary drive gear bolt
Bearing set plate bolt
Crankshaft Bearing set plate bolt
Countershaft Bearing set plate torx
screw
Transmission oil drain bolt
Neutral switch (hole plug bolt)
Piston jet mounting bolt
54 N-m (5.5 kgf-m, 40 Ibf-ft)
12N-m(1.2kgfm, 9 Ibfft)
108 N-m (11.0 kgfm, 80 Ibf-ft)
12 N-m (1.2 kgfm, 9 Ibf-ft)
16 N-m (1.6 kgf-m, 12 Ibf-ft)
12 N-m (1.2 kgf-m, 9 Ibf-ft)
22 N-m (2.2 kgf-m, 16 Ibf-ft)
12 N-m (1.2 kgf-m, 9 Ibf-ft)
10 N-m (1.0 kgf-m, 7 Ibf-ft)
Apply oil to the threads and seating surface.
Replace with a new one and stake.
Apply locking agent to the threads.
Apply oil to the threads and seating surface.
Apply locking agent to the threads.
Apply locking agent to the threads.
Apply locking agent to the threads.
Apply oil to the threads and seating surface.
Apply locking agent to the threads.
16-3