Gear Shift and Select Shaft Assembly

GEAR SHIFT & SELECT SHAFT ASSEMBLY





1. To disassemble component parts, use special tools and 2.8 - 3.0 mm (0.11 inch) pin remover in addition.
Special Tools
(A): 09922-85811 (4.5 mm)
(B): 09925-78210 (6.0 mm)
2. Clean all parts thoroughly, inspect them and replace with new ones as required.
3. Assemble component parts by reversing removal procedure.

NOTE:
- When driving in spring pins, prevent shaft from being bent by supporting it with wood block.
- Assemble 5th & REV gear shift cam by winding cam guide return spring, and then drive in spring pin.
- Locate low speed select spring (Lower position) and reverse select spring (Yellow- Upper position) correctly.

HIGH SPEED AND LOW SPEED GEAR





1. Using feeler gauge, check clearance between fork and sleeve and replace those parts if it exceeds limit of 1.0 mm (0.039 inch).

NOTE: For correct judgement of parts replacement, carefully inspect contact portion of fork and sleeve.

Clearance "a": Service limit 1.0 mm (0.039 inch)
2. Insert each gear shift shaft into case and check that it moves smoothly. If it doesn't, correct by using oilstone, reamer or the like.





3. Disassemble component parts by using spring pin remover and hammer.
Special Tool
(A): 09922-85811 (4.5 mm)
4. Assemble shift shafts as shown while making sure that component parts are in proper order.

NOTE:
- Correct shaft surface by using oilstone, if any scratch or dent is found.
- Support shaft with wood blocks when driving in spring pins.

Tightening Torque
(a): 10 Nm (1.0 kg.m, 7.5 ft. lbs.)

5TH & REV GEAR SHIFTER





1. Disassemble component parts by using spring pin remover and hammer.
Special Tool
(A): 09922-85811 (4.5 mm)
2. Replace or correct parts as required and assemble shafts making sure that component parts are in proper order as shown.

NOTE: Install 2 steel balls in reverse gear shift arm without fail.