Transmission Assembly

SAFETY FIRST: Protective gloves and eyewear are recommended at this point.

Installation

Apply fresh engine oil to all the areas of the shaft where a gear or bearing rides or slides and the outside of all bearings.

Press in the driven shaft until it is flush with its bearing.

Lubricate the needle bearings with oil and slide them onto the driven shaft.

Slide the low gear (20T) onto the driven shaft.

Fit the needle bearing onto the outside of the low gear.

Install the spacer (48.2 x 54.3 x 1.0) onto the driven shaft.

The high gear should still have its internal spacer (48.2 x 54.3 x 1.0) on the inside. Install the high gear (26T) and its internal spacer onto the driven shaft.

Fit the high-low spacer onto the driven shaft and into the high gear.

Fit the spacer (28.2 x 34.5 x 1.6) onto the driven shaft.

Install the spline washer (T = 1.5) onto the driven shaft.

Lift up on the high gear on the driven shaft and install the idle shaft.

Install the spacer (20.3 x 33 x 2.0) onto the end of the idle shaft.

Install a new snap ring into the groove on the driven shaft with snap ring pliers.

Fit the shift fork into the groove on the shifter. Install the shifter onto the driven shaft and the shift fork shaft into the crankcase.

Install the spacer (21.2 x 29 x 1.6) onto the driven shaft. Fit the needle bearing onto the driven shaft. Install the reverse drive gear (12T) onto the driven shaft.

Install the spacer (17.3 x 30 x 2.0) onto the driven shaft.

Install the reverse idle shaft.

Lubricate the shift shaft with molybdenum disulfide grease. Apply a non-permanent thread locking agent (Blue Loctite) to the spring bolt. Fit the shift shaft into place.

Tighten the shift shaft spring bolt to specification with a 6 mm Allen.

Shift Shaft Spring Bolt: 25 N-m, 2.5 kgf-m, 18 ft-lb

Install a new shift shaft cover gasket.

Install the shift shaft cover.

Install the three shift shaft cover bolts and tighten them to specification with an 8 mm socket.

Shift Shaft Cover Bolts: 8.8 N-m, 0.9 kgf-m, 78 in-lb

Fit the shift shaft lever onto the shaft so that it sits in its original position. Install the shift shaft pinch bolt and tighten it securely with a 10 mm socket.

Assemble the crankcases. See the Crankcases topic for more information.