Transmission

Transmission

• Remove the cotter pin [A], and pull out the 3rd/4th shift fork guide pin [B].

• Remove the bolts [A] holding the shift drum ball bearing [B].

• Pull out the shift drum [C] slightly, and remove the 3rd/4th shift fork. Pull the shift drum free from the crankcase.

Shift Drum and Fork Installation

• Insert the shift drum [A] into the crankcase part way, install the 3rd/4th shift fork [B] with the longer side [C] facing the neutral switch, i.e., the longer side goes onto the drum first.

• Push the shift drum in the rest of the way.

• Apply a non-permanent locking agent to the threads of the holding bolts, and tighten them.

Torque-Shift Drum Bearing Holding Bolts: 11 N-m (1.1 kgf-m, 95 in-lb)

• Put the shift fork guide pin [A] with the pin hole upward into the 3rd/4th shift fork. The guide pin rides in the middle groove of the three shift drum grooves.

• Insert a new cotter pin through the 3rd/4th shift fork and guide pin from the shorter side of the shift fork, and spread the cotter pin longer side.

9-32 CRANKSHAFT/TRANSMISSION

• Install the washer, spring, gear positioning lever, collar and nut.

• Set the shift drum in the neutral position, that is, fit the gear positioning lever [A] into the detent on the shift drum cam [B].

• Install the shift shaft.

• Apply a little engine oil to the shift rod and shift fork ears. Insert the shift rod [A], running it through the shift forks [B], fitting each shift fork guide pin into the shift drum groove. The shift forks are identical, and must be installed with their longer sides [C] facing toward the external shift mechanism.

Shift Drum Disassembly

• Remove the screw [A] and the pin plate [B].

• Pull out the shift drum cam [C].

• Take off the ball bearing [D]. Pull off the dowel pin [E].

Shift Drum Assembly

• Set the dowel pin [A] into larger hole of the two which is the farthest hole from the center.

• Install the shift drum cam aligning its groove [A] with the dowel pin [B].

CRANKSHAFT/TRANSMISSION 9-33 Transmission

• There are six points on the shift drum cam. The highest point [A] must be fitted into the back of the pin plate [B]. If these parts are assembled in the wrong position, the neutral indicator light will not light when the gears are in neutral.

• Apply a non-permanent locking agent to the threads of the pin plate screw.

• Tighten the pin plate screw.

Ball and Needle Bearing Wear

• Check the following ball bearings: shift drum LH, drive
shaft RH, and output shaft LH.

OSince the ball bearings are made to extremely close toler­ances, the wear must be judged by feel rather than mea­surement. Clean each bearing in a high flash-point sol­vent, dry it (do not spin the bearing while it is dry), and oil it with engine oil.

OSpin the bearing by hand to check its condition.

• If the bearing is noisy, does not spin smoothly, or has any rough spots, replace it.

• Check the following needle bearings: drive shaft LH and output shaft RH.

OThe rollers in a needle bearing normally wear very little, and wear is difficult to measure. Instead of measuring, inspect the bearing for abrasion, color change, or other damage.

• If there is any doubt as to the condition of a needle bear­
ing, replace it.

Shift Pedal Installation

• Install the shift pedal [A] adjusting the length [B] of the
shift rod [E] so that the height of the tip (a part of rubber)
of shift pedal is almost same as the one of the drive chain
guide installation lower bolt [D].

Дата добавления: 2014-12-23