SAFETY FIRST: Protective gloves and eyewear are recommended at this point.
Removal
Split the crankcases. See the Crankcases for more information.
The shift shaft cover is located in the top of the right crankcase half. Mark the position of the shift shaft lever so that it can be returned to its original position.
Loosen the shift shaft pinch bolt with a 10 mm socket.
Remove the shift shaft pinch bolt and the shift shaft lever from the shaft.
Remove the three shift shaft cover bolts with an 8 mm socket.
Remove the shift shaft cover and gasket.
Inspect the shift shaft oil seal and replace it as needed. If the oil seal is to be replaced drive in the replacement by its outside diameter so that it fits flush with the cover.
Loosen the shift shaft spring bolt with a 6 mm Allen.
Lift out the shift shaft.
The transmission shafts are located in the right crankcase half.
Lift out the reverse idle shaft.
Remove the spacer (17.3 x 30 x 2.0) from the driven shaft.
Remove the reverse drive gear (12T) from the driven shaft.
Remove the needle bearing from the driven shaft.
Remove the spacer (21.2 x 29 x 1.6) from the driven shaft.
Remove the shifter from the driven shaft. Remove the shift for and shift shaft.
Remove the snap ring with snap ring pliers.
Remove the spacer (20.3 x 33 x 2.0) from the idle shaft.
Lift up on the high gear on the driven shaft and remove the idle shaft.
Remove the spline washer (T = 1.5) from the driven shaft.
Remove the spacer (28.2 x 34.5 x 1.6) from the driven shaft.
Remove the high-low spacer from the driven shaft. Also, note the large spacer (48.2 x 54.3 x 1.0) inside of the high gear.
Lift the high gear (26T) and its internal spacer (48.2 x 54.3 x 1.0) off of the driven shaft.
Remove the spacer (48.2 x 54.3 x 1.0) from the driven shaft.
Remove the needle bearings from the low gear.
Slide off the low gear (20T) off of the driven shaft.
Slide the two needle bearings off of the driven shaft.
To remove the driven shaft from the case press it out from the right side.
Inspection
Inspect the gears on the idle shaft. Use a press to remove and install these gears as needed.
Inspect the gears on reverse idle shafts. Use a press to remove and install these gears as needed.
Inspect the condition of the shift shaft and fork. The fork should be permanently attached to the shaft at a 90° angle. Measure the thickness of the shift fork ears where it will contact the shifter. Also, measure the width of the shifter groove. Replace the components as needed.
Shift Fork Ear Thickness: 5.9 – 6.0 mm (0.2322 – 0.2362 in.)
Service Limit: 5.8 mm (0.228 in.)
Shifter Groove Width: 6.05 – 6.15 mm (0.2382 – 0.2421 in.)
Service Limit: 6.25 mm (0.246 in.)
Inspect the teeth, dogs, and slots of the gears and shifter. Replace the parts as needed.
Inspect the transmission bearings. See the Crankcase Bearings topic for more information.
To install the transmission see the Transmission Assembly topic.