10.CRANKCASE/CRANKSHAFT/TRANS-
MISSION SYSTEM/STARTER SPINDLE Pulsar CK 125
Main Shaft Countershaft
TRANSMISSION GEARS/
CRANKSHAFT REMOVAL
Remove the transmission main shaft and
countershaft from the right crankcase.
When removing, the transmission gears
must be removed as a set.
Remove the crankshaft.
Disassemble the main shaft and countershaft.
GEAR/SHAFT COLLAR INSPECTION
Check each gear and gear teeth for wear,
damage, or poor lubrication.
Measure each gear I.D.
Service Limits:
Main shaft 4th/5th gear: 20.061mm replace
if over
Countershaft 3rd gear: 20.061mm replace if
over
Measure each shaft collar I.D.
Service Limits:
Countershaft starter idle gear: 16.85mm
replace if over
Countershaft 1st gear: 16.85mm replace if
over
Measure each shaft collar O.D.
Service Limits:
Countershaft starter idle gear: 19.55mm
replace if
below
Countershaft 1st gear: 19.0mm replace if below
Shaft Collar
10-5