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.
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