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ENGINE BOTTOM END/TRANSMISSION 7-15
Transmission
•
Install the shift drum.
•
Fit the shift fork guide pins into the corresponding shift
drum grooves.
•
Apply a little transmission oil to the shift rods, and slide
them into the shift forks.
•
Holding the shift drum with the suitable tool and tighten
the shift drum operating plate bolt.
○
Apply a non-permanent locking agent to the shift drum
operating plate bolt.
Torque - Shift Drum Operating Plate Bolt: 24 N·m (2.4
kgf·m, 17 ft·lb)
Shift Fork Bending Inspection
•
Visually inspect the shift forks, and replace any fork that is
bent. A bent fork could cause difficulty in shifting, or allow
the transmission to jump out of gear when under power.
[A] 90°
Shift Fork/Gear Groove Wear Inspection
•
Measure the thickness of the shift fork ears [A], and mea-
sure the width [B] of the shift fork grooves in the transmis-
sion gears.
If the thickness of a shift fork ear is less than the service
limit, the shift fork must be replaced.
Shift Fork Ear Thickness
Standard:
3.90 ∼ 4.00 mm
Service Limit:
3.80 mm
If a gear shift fork groove is worn over the service limit,
the gear must be replaced.
Shift Fork Groove Width
Standard:
4.05 ∼ 4.15 mm
Service L i m it :
4.25 mm
Shift Fork Guide Pin/Shift Drum Groove Wear
Inspection
•
Measure the diameter [A] of each shift fork guide pin, and
measure the width [B] of each shift drum groove.
If the guide pin on any shift fork is less than the service
limit, the fork must be replaced.
Shift Fork G uide Pin Diameter
Standard:
5.90 ∼ 6.00 mm
Service L i m it :
5.80 mm
If any shift drum groove is worn over the service limit, the
drum must be replaced.
Shift Drum Groove Width
Standard:
6.05 ∼ 6.20 mm
Service Limit:
6.25 mm