Gear Shifter
GEAR SHIFTERGear 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 Tool
(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 (Green-Lower position) and reverse select spring (Upper position) correctly.
High Speed and Low Speed Gear Shift Shafts
1. Before disassembling shift shaft assemblies, determine necessity of parts replacement by checking them for abnormal wear or distortion. Use feeler gauge for checking clearance "a" between sleeve and shift fork.
NOTE: For correct judgment of parts replacement, carefully inspect contact portion of fork and sleeve.
Maximum clearance "a": 1.0 mm (0.039 inch)
2. Disassemble component parts by using special tool and hammer.
Special Tool
(A): 09922-85811 (4.5 mm)
3. Assemble shift shafts as shown left while making sure that component parts are in proper order.
NOTE:
- Correct shaft surface by using oil stone, if any scratch or dent is found.
- Support shaft with wood blocks when driving in spring pins.
5th & REV Gear Shifter
1. Disassemble component parts by using special tool 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 left.
NOTE:
- Distinguish reverse gear shift arm spring (Blue) from low speed locating spring (Purple).
- Install 2 steel balls in reverse gear shift arm without fail.
- Drive in spring pin for reverse shift arm facing slit A toward front.