Reassembly

Page 39       



Install Fork Shafts

a. Install first and second fork shaft (13) in fork shaft hole furthest away from case cover. As fork shaft is
    installed, insert into first and second shift fork.
b. Assemble washer (2) and bolt (3). Tighten to 14 lb ft torque.
c. Install long detent dowel (5).
d. Install third and fourth fork shaft (15) in center fork shaft holes. As fork shaft is installed, insert into third     and fourth shift fork. Also install detent pin (14) into fork shaft (15).
e. Assemble washer (2) and bolt (3). Tighten to 14 lb ft torque.
f. Temporarily install two detent balls (8) and two springs (9) for installed fork shafts. Assemble cover (11)
    and two bolts (12).
g. Engage two gear's to lock the transmission.
h. Tighten 27-mm nut (4) to 87 ib ft, and 19-mm bolt to 69 lb ft torque. Disengage two gears.
i.  Check that both countershaft and main shaft can be easily turned. If countershaft cannot be turned, its
   rear bearing may be installed backwards. Also engage each gear and check for free turning.
j.  Using staking pliers A.74140/1 and staking heads A.74140/4, stake nut (4).
k. Install short detent dowel (6).
l. Install fifth and reverse fork shaft (1) into fifth and reverse shift fork, and into remaining fork shaft hole.
m. Assemble washer (2) and bolt (3). Tighten to 14 lb ft torque.
n. Remove bolt (12) and cover (11). Install third detent ball (8) and spring (9).
o. Install new gasket (10) (sealant is not recommended), cover (11), and two bolts (12). Tighten bolts to
   18 lb ft torque.
p. Engage a gear. Check that a second gear cannot be engaged at the same time.

 

1 . Fifth and reverse fork shaft
2. Lockwasher
3. Bolt
4. 27-mm nut
5. Long detent dowel
6. Short detent dowel
7. 19-mm bolt
8. Detent ball
9. Spring
10. Gasket
11. Cover
12. Bolt
13. First and second fork shaft
14. Detent pin
15. Third and fourth fork shaft


 

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