Transmission. When installing the 5th gear and steel balls on the output shaft, do not apply grease to the balls to hold them in place

When installing the 5th gear and steel balls on the output shaft, do not apply grease to the balls to hold them in place. This will cause the positive neutral finder mechanism to malfunction.

CAUTION

Transmission

• Install the spacer onto the drive shaft, facing the cham­fered side to the ball bearing.

• Check that each gear spins or slides freely on the drive shaft without binding.

Output Shaft Assembly

• Assembly is the reverse of disassembly. Note the follow­ing.

• Apply engine oil liberally to the output shaft, gears, bear­ings, bushing and O-ring.

• Install the output shaft ball bearing, O-ring and collar us­ing the bearing driver.

Special Tool - Bearing Driver, 3 2: 57001-382

OThe ball bearing, O-ring and collar ought to be installed individually.

• Replace any circlips that were removed with new ones.

OAlways install circlips so that the opening is aligned with a spline groove. To install a circlip without damage, fit the circlip onto the shaft expanding it only enough to install it, and use a suitable gear to push the circlip into place.

Circlip

Toothed Washer

• When assembling the output shaft 3rd/4th gear bushing [A] to the shaft, align its oil holes [B] with the holes in the shaft.

9-30 CRANKSHAFT/TRANSMISSION

• Check the effect of ball-locking, after assembling the 5th gear and steel balls on the output shaft.

○Check that the 5th gear [A] does not come out of the out­put shaft when moving it up and down by hand.

• The output shaft gears can be identified by size: the largest diameter gear is 1st gear, and the smallest is 6th. Be sure that all parts are put back in the correct sequence and facing the proper direction, and that all circlips and washers are properly in place.

• Proper sequence starting with 2nd gear is: 2nd gear (face the flat side of the gear to the left), toothed washer, circlip, 6th gear (face the fork groove side to the right), circlip, toothed washer, bushing (align the oil holes with the holes in the shaft), 4th gear (face the side with the dog recesses to the left), 3rd gear (face the side with the dog recesses to the right), toothed washer, circlip, 5th gear (face the fork groove side to the left) with steel balls (3), 1st gear (face the flat side of the gear to the right), spacer, needle bearing, and needle bearing outer race.

• Press the oil seal [A] onto the collar [B] so it is flush with the end of collar.

• Check that each gear spins or slides freely on the output shaft without binding.

Shift Drum and Fork Removal

• Remove:

Lower Crankcase Half (see Crankcase Splitting) External Shift Mechanism (see External Shift Mecha­nism Removal)

• Pull out the shift rod [A], and remove the two shift forks
[B] in the lower crankcase half.

CRANKSHAFT/TRANSMISSION 9-31

Дата добавления: 2014-12-23