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CRANKSHAFT/TRANSMISSION 8-21
Transmission
•
Apply high temperature grease to the seal lips.
•
Insert the shift shaft into the cover [A], and then fit the shift
mechanism arm [B] to the shift drum [C].
•
Tighten the cover bolts.
Torque - External Shift Mechanism Cover Bolts: 11 N·m
(1.1 kgf·m. 95 in·lb)
•
Check:
Engine Oil Level (see Engine Lubrication System chap-
ter)
Drive Chain Slack (see Final Drive chapter)
External Shift Mechanism Inspection
•
Examine the shift shaft for any damage.
○
Check the shift shaft for bending or damage to the splines
[A].
If the shaft is bent, straighten or replace it. If the splines
are damaged, replace the shaft.
○
Check the return spring [B] and arm spring [C] for breaks
or distortion.
If the springs are damaged in any way, replace them.
○
Check the shift mechanism arm [D] for distortion.
If the shift mechanism arm is damaged in any way, re-
place the arm.
•
Check that the return spring pin [A] is not loose.
If it is loose, unscrew it, apply a non-permanent locking
agent to the threads, and tighten it.
Torque - Return Spring Pin: 20 N·m (2.0 kgf·m, 14.5 ft·lb)
•
Check the gear positioning levers [B], and their springs
[C] for break or distortion.
If the levers or springs are damaged in any way, replace
them.
•
Visually inspect the shift drum cam [D] and pin plate [E].
If they are badly worn or if they show any damage, replace
them.
Transmission Shaft Removal
•
Remove the engine (see Engine Removal/Installation
chapter).
•
Split the crankcase (see Crankcase Splitting).
•
Take out the output shaft assembly.
•
Lift up the drive shaft assembly, and pull the shaft assem-
bly out of the clutch housing. Leave the clutch housing
and primary chain in place.