11. High and Low Speed Gear Shafts Disassembly and Assembly

High Speed and Low Speed Gear Shift Shafts Disassembly and Assembly





1. Using feeler gauge, check clearance between fork (1) and sleeve (2) and replace those parts if it exceeds limit of 1.0 mm (0.039 inch).

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

Clearance "a" between fork and sleeve
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.
^ Apply thread lock cement to shift fork bolts.

"A": Thread lock cement 99000-32110
Tightening torque
Shift fork bolts (a): 10 Nm (1.0 kgf-cm, 7.5 ft. lbs.)