Transmission. • Apply high temperature grease to the seal lips

• Apply high temperature grease to the seal lips.

• Insert the shift shaft into the crankcase half and fit the shift mechanism arm [A] to the shift drum [B].

• Install the external shift mechanism cover.

• Tighten the cover bolts.

Torque - External Shift Mechanism Cover Bolts: 11 N-m (1.1 kgf-m. 95 in-lb)

• Check:

Engine Oil Level (see Engine Oil Level Inspection in the Engine Lubrication System chapter) Drive Chain Slack (see Drive Chain Slack Inspection in the Periodic Maintenance chapter)

External Shift Mechanism Inspection

• Examine the shift shaft for any damage.

OCheck the shift shaft for bending or damage to the splines

[A].

• If the shaft is bent, straighten or replace it. If the splines
are damaged, replace the shaft.

OCheck the return spring [B] and arm spring [C] for breaks or distortion.

• If the springs are damaged in anyway, replace them.
OCheck the shift mechanism arm [D] for distortion.

• If the shift mechanism arm is damaged in any way, re­
place the arm.

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Check that the return spring pin [A] is not loose.

If it is loose, unscrew it, apply a non-permanent locking

agent to the threads, and tighten it.

Torque - Return Spring Pin: 20 N-m (2.0 kgf-m, 14.5 ft-lb)

Check the gear positioning levers [B], and their springs

[C] for break or distortion.

If the levers or springs are damaged in any way, replace

them.

Visually inspect the shift drum cam [D] and pin plate [E].

If they are badly worn or if they show any damage, replace

them.

Transmission Shaft Removal

• Remove the engine (see Engine Removal in the Engine Removal/Installation chapter).

• Split the crankcase (see Crankcase Splitting).

• Take out the output shaft assembly.

• Lift up the drive shaft assembly, and pull the shaft assem­bly out of the clutch housing. Leave the clutch housing and primary chain in place.

Transmission Shaft Installation

• With a high flash-point solvent, clean off the outer cir­
cumferences of the transmission ball bearings and needle
bearings, and their bearing housings, and wipe dry.

CRANKSHAFT/TRANSMISSION 9-27