Transmission

TRANSMISSION

1. Inspect:
• Shift fork cam follower 1
• Shift fork pawl 2
• Guide bar 3  

Scoring/Bends/Wear->  Replace.

2. Inspect:
• Shift cam groove
• Shift cam dowel and side plate 1
• Shift cam stopper plate 2
• Neutral point 3

 Wear/Damage ->  Replace.

3. Measure the transmission shaft runout. Use a centering device and dial gauge. Replace shaft if bent.

Maximum Runout: 0.08 mm (0.0031 in)

4. Inspect the gear teeth 1 for: Blue discoloration/Pitting/Wear.  Inspect the mated dogs 2 for Rounded edges/Cracks/Missing portions. Replace as necessary.

Note:
Minor rounding of the dogs can be corrected by undercutting. See the article on "Repairing second gear" elsewhere on this site.


5. Check:

• Proper gear engagement (Each gear to its counter part). Incorrect->  Reassemble. 
• Gear and bearing movement. Roughness->  Replace.

SHIFTER

1. Inspect:
• Shift return spring 1
• Stopper lever spring 2
• Shift lever spring 3  

Damage -> Replace.

• Shift shaft 4
• Shift lever 5  

Damage/Bends/Wear -> Replace.

CRANKCASE 

1. Inspect: 
• Case halves
• Bearing seat
• Fitting

Damage -> Replace.

BEARINGS AND OIL SEALS

1.  Inspect each bearing. Clean and lubricate, then rotate inner race with finger.

Roughness ->  Replace bearing (see Removal).

2.  Inspect all oil seals. Replace any damaged or worn seals.

CIRCLIPS AND WASHERS

1. Inspect:
• Circlips 
• Washers

Damage/Looseness/Bends -> Replace.