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9-38 CRANKSHAFT/TRANSMISSION
Transmission
Shift Fork Bending
•
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.
90° [A]
Shift Fork/Gear Groove Wear
•
Measure the thickness of the shift fork ears [A], and mea-
sure the width [B] of the gear grooves.
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: 5.9 ∼ 6.0 m m (0.232 ∼ 0.236 in.)
Service Limit: 5.8 mm (0.228 in.)
If the gear groove is worn over the service limit, the gear
must be replaced.
Gear Groove Width
Standard: 6.05 ∼ 6.15 mm (0.238 ∼ 0.242 in.)
Service Limit: 6.2 5 mm (0.246 in.)
Shift Fork G uide Pin/Drum Groove Wear
•
Measure the diameter of each shift fork guide pin [A], 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 Guide Pin Diameter
Standard: 5.9 ∼ 6.0 m m (0.232 ∼ 0.236 in.)
Service Limit: 5.8 mm (0.228 in.)
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 (0.238 ∼ 0.244 in.)
Service Limit: 6.3 mm (0.248 in.)
Gear Dog and Gear Dog Hole Damage
•
Visually inspect the gear dogs [A] and gear dog holes [B].
Replace any damaged gears or gears with excessively
worn dogs or dog holes.
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