sm - kymco vitality 50 - chapter 11 (crankcase - crankshaft)
TRANSCRIPT
11. CRANKCASE/CRANKSHAFT
11-0
VITALITY 50
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CRANKCASE/CRANKSHAFT__________________________________________________________________________________
SERVICE INFORMATION........................................................ 11- 3CRANKCASE/CRANKSHAFT (2-STROKE)............................... 11- 4CRANKCASE/CRANKSHAFT (4-STROKE)............................... 11-10
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11. CRANKCASE/CRANKSHAFT
11-1
VITALITY 50
(2-STROKE)
Torque: 0.8_ 1.2kg-m
11. CRANKCASE/CRANKSHAFT
11-2
VITALITY 50
(4-STROKE)
11. CRANKCASE/CRANKSHAFT
11-3
VITALITY 50
SERVICE INFORMATION
GENERAL INSTRUCTIONS
• This section covers crankcase separation to service the crankshaft. The engine must be removedfor this operation.
• The following parts must be removed before separating the crankcase.−Cylinder head (Chapter 6 (2-stroke))−Cylinder/piston (Chapter 7)−Drive and driven pulleys (Chapter 9)−A.C. generator (Chapter 8)
SPECIFICATIONS (2-Stroke)
Item Standard (mm) Service Limit (mm)Connecting rod big end side clearance 0.6
Crankshaft Connecting rod big end radial clearance 0.04
Run out A/B 0.1/0.15
SPECIFICATIONS (4-Stroke)
Item Standard (mm) Service Limit (mm)Connecting rod small end free play 0.05_ 0.4 0.6
Crankshaft Connecting rod big end radial clearance 0_ 0.008 0.05
Run out 0.10
TORQUE VALUESCrankcase bolt 0.8_ 1.2kgf-mCam chain tensioner slipper bolt 0.8_ 1.2kgf-m (4-Stroke)
SPECIAL TOOLS (2-stroke)
Crankcase puller E026Universal bearing puller E030Crankshaft install tool E016Crankcase assembly tool E024Oil seal and bearing install tool E014
TROUBLESHOOTING
Abnormal engine noise• Excessive crank journal bearing play• Excessive crankpin bearing play• Excessive transmission bearing play
11. CRANKCASE/CRANKSHAFT
11-4
VITALITY 50
CRANKCASE/CRANKSHAFT
(2-STROKE)SEPARATIONRemove the crankcase attaching bolts.
Attach the crankcase puller on the rightcrankcase and remove the right crankcasefrom the left crankcase.
Crankcase puller E026
CRANKSHAFT REMOVAL
Attach the crankcase puller on the leftcrankcase and remove the crankshaft fromthe left crankcase.
Crankcase puller E026
When removing the crankshaft, do itslowly and gently.
°Ø
Crankcase Puller
Crankcase Puller
Bolt
Special
Special
11. CRANKCASE/CRANKSHAFT
11-5
VITALITY 50
Remove the remaining bearing on thecrankshaft side using the universal bearingpuller.
Crankshaft bearing puller E030
CRANKSHAFT INSPECTION
Measure the connecting rod big end sideclearance.Service Limit: 0.6mm replace if over
Measure the connecting rod big end radialclearance at two points in the X and Ydirections.Service Limit: 0.04mm replace if over
When separating the crankcase, the oilseals must be removed. Replace the oilseals with new ones.
°Ø
Universal Bearing Puller
Special
11. CRANKCASE/CRANKSHAFT
11-6
VITALITY 50
Measure the crankshaft runout.
Service Limit
A B
0.150mmreplace if over
0.100mmreplace if over
Check the crankshaft bearings for excessiveplay. The bearings must be replaced if theyare noisy or have excessive play.
CRANKSHAFT INSTALLATION
Wash the crankshaft in cleaning solvent andthen check for cracks or other faults.
•After check, apply clean engine oil toall moving and sliding parts.
• Remove all gasket material from thecrankcase mating surfaces. Dress anyroughness or irregularities with an oilstone.
°Ø
Axial
PlayPlay
Radial
11. CRANKCASE/CRANKSHAFT
11-7
VITALITY 50
Drive a new crankshaft bearing into theright crankcase.
Oil seal & bearing install E014
The distance between the left crankcase oilseal and crankcase surface is about 1.0mm.
Drive a new crankshaft bearing into the leftcrankcase.
Oil seal & bearing install E014
The distance between the right crankcase oilseal and crankcase surface is about 12.5±0.5mm.
Bearing Outer Driver Handle A
Bearing Outer Driver Handle A
Bearing Outer Driver, 37x40mmBearing Driver Pilot, 17mm
Bearing Outer Driver, 42x47mmPilot, 20mm
Special
Special
When installing the oil seal, be careful topress it with even force.
°Ø
Oil Seal
1.0mm
11. CRANKCASE/CRANKSHAFT
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VITALITY 50
ASSEMBLY
Install the dowel pins and a new gasket tothe crankcase mating surface.
Assemble the crankcase halves.
Crankcase assembly tool E024
Dowel Pins
Crankcase Assembly Tool
Crankcase Assembly Tool
Special
11. CRANKCASE/CRANKSHAFT
11-9
VITALITY 50
Install and tighten the crankcase bolts in acrisscross pattern in several steps.
Bolt
After assembly, check the crankshaftfor smooth operation.
°Ø
11. CRANKCASE/CRANKSHAFT
11-10
VITALITY 50
CRANKCASE/CRANKSHAFT
(4-STROKE)
REMOVAL
Remove nuts and take out the bolts fromcenter stand.
Remove spring and center stand fromcrankcase.
Remove the crankcase attaching bolt.Separate the left and right crankcase halves.
Nuts/Bolts
Spring
Bolt
Center Stand
• Do not damage the crankcasegasket surface.• Never use a driver to pry the
crankcase mating surfaces apart.
°Ø
11. CRANKCASE/CRANKSHAFT
11-11
VITALITY 50
Remove the crankshaft from the leftcrankcase.
Remove the cam chain.Remove the gasket and dowel pins.
Clean off all gasket material from thecrankcase mating surfaces.
Dowel Pins
Gasket
RadialAxial
Avoid damaging the crankcase matingsurfaces.
°Ø
Crankshaft
Cam Chain
11. CRANKCASE/CRANKSHAFT
11-12
VITALITY 50
CRANKSHAFT INSPECTIONMeasure the connecting rod small end I.D.Service Limit: 13.06 mm replace if over
Measure the connecting rod small end freeplay (A).Out of specification (0.05 ~ 0.4 mm) _Replace the crankshaft.
Measure the crankshaft run out (B).Service Limit: 0.10mm replace if over
Measure the connecting rod big end sideclearance (C).Service Limit: 0.05mm replace if over
Measure the crank width (D).Out of specification (42.2 ~ 42.15 mm) _Replace the crankshaft.
Turn the crankshaft bearings and check forexcessive play.Measure the crankshaft bearing play.Service Limit: Axial : 0.20mm replace if over Radial : 0.05mm replace if over
A
B B
CD
Play
Play
RadialAxial
11. CRANKCASE/CRANKSHAFT
11-13
VITALITY 50
CRANKCASE/BALANCERINSTALLATIONInstall the cam chain into the left crankcase.
Install the dowel pins and a new gasketonto the left crankcase.
Install the crankshaft into the left crankcase.
Install the right crankcase.Tighten the crankcase attaching bolt.Torque: 0.8~1.2kgf-m
Bolt
Place the right crankcase over thecrankshaft and onto the left crankcase.
°Ø
When installing the crankshaft, be carefulnot to damage the oil seal.
°Ø