Balancer Shaft Bearing Insert Selection

Crankcase Main Bearing Bore Diameter Mark	Crankshaft Main Journal Diameter Mark	Bearing Insert*
		Size Color	Part Number
○	○	Brown	92139-0119
○	None	Black	92139-0118
None	○
None	None	Blue	92139-0117

Shift Pedal Removal

_• Remove:

Shift Lever Bolt [A]

Shift Lever [B]

Shift Pedal Installation

_• Align the mark [A] on the shift shaft with the slit [B] on the shift lever.

_• Tighten the shift lever bolt securely.

_• Be sure the shift pedal position is as shown. Shift Pedal Damper [A]

Bottom [B] of Left Footpeg Stay Shift Lever [C]

Bolt [D] of Left Footpeg Stay

External Shift Mechanism Removal

_• Remove:

Engine Oil (Drain, see Engine Oil Change in the Periodic

Maintenance chapter)

Shift Pedal (see Shift Pedal Removal)

Engine Sprocket (see Engine Sprocket Removal in the Final Drive chapter)

Neutral Switch Lead Connector (Disconnect) Shift Shaft Cover Bolts [A]

Shift Shaft Cover Screw [B] Shift Shaft Cover [C]

_• Remove the shift shaft assembly [A].

_• Remove:

Clutch (see Clutch Removal in the Clutch chapter)

Gear Positioning Lever Bolt [A]

Gear Positioning Lever [B], Spacer, Washer and Spring

External Shift Mechanism Installation

_• Install the gear positioning lever [A] as shown. Spring [B]

Washer [C] Spacer [D] Bolt [E]

○^{Hook the spring at gear positioning lever, pushing up [F]}

the hook portion, as shown.

_• Apply a non-permanent locking agent to the gear posi- tioning lever bolt and tighten it.

Torque - Gear Positioning Lever Bolt: 12 N·m (1.2 kgf·m, 106 in·lb)

_• Install the shift shaft assembly.

○^{Apply [A] molybdenum disulfide oil solution to the rub-}

bing surface between the lever [B] and pawl [C] and move

them two or three times up and down to lubricate them.

○^{Be sure that the washer [A] is on the shaft.}

○^{Be sure that the spring hook portions [B] are as shown.}

_• When the new needle bearing [A] is installed in the shift shaft cover [B], press and insert the new needle bearing

until it is bottomed.

Special Tool - Bearing Driver Set: 57001-1129

_• When the new oil seal [C] is installed in the shift cover, press and insert the new oil seal so that its surface is flush

with the end of the hole.

Special Tool - Bearing Driver Set: 57001-1129

_• Install the shift shaft cover.

○^{Be sure that the dowel pins [A] are in position.}

○^{Install the new gasket [B].}

_• Apply a non-permanent locking agent to the shift shaft cover screw [A] and bolts [B, C] and tighten them.

○^{Do not apply a non-permanent locking agent to the shift}

shaft cover bolts [D, E].

○^{Tighten the cover screw lastly.}

Torque - Shift Shaft Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)

Shift Shaft Cover Screw: 4.9 N·m (0.50 kgf·m, 43 in·lb)

External Shift Mechanism Inspection

_• Examine the shift shaft [A] for any damage. If the shaft is bent, straighten or replace it.

If the serration [B] are damaged, replace the shaft.

If the springs [C] are damaged in any way, replace them. If the shift mechanism arm [D] is damaged in any way, replace the arm.

_• Check the return spring pin [A] is not loose.

If it is loose, unscrew it, apply a non-permanent locking

agent to the threads, and tighten it.

Torque - Shift Shaft Return Spring Pin: 29 N·m (2.9 kgf·m, 21 ft·lb)

_• Check the gear positioning lever [A] and its spring for breaks or distortion.

If the lever or spring are damaged in any way, replace them.

_• Visually inspect the shift drum cam [B].

If they are badly worn or if they show any damage, replace

it.

Transmission Assy Removal

_• Remove:

Shift Shaft Assembly (see External Shift Mechanism Re-

moval)

Neutral Switch Holder Bolt [A] Neutral Switch Holder [B] and Pin Shift Drum Holder [C] and Pin

_• Remove: Collar [A]

15. ring [B]

_• Remove:

Clutch (see Clutch Removal in the Clutch chapter)

Transmission Case Bolts [A]

If the transmission assy is to be disassembed, remove the following.

Shift Rod Plate Bolt [B] Shift Rod Plate [C]

Gear Positioning Lever Bolt [D]

Gear Positioning Lever [E] with Spring, Washer and Spacer

_• Pull the transmission assy [A] out of the crankcase.

Transmission Assy Disassembly

_• Remove the transmission assy (see Transmission Assy Removal).

_• Remove the following from the transmission case [A].

Shift Rods [B]

Shift Forks [C] Drive Shaft [D] Output Shaft [E]

_• Remove:

Shift Drum Cam Bolt [A]

Shift Drum [B] and Pin Shift Drum [C]

Transmission Assy Assembly

_• When the new ball bearings [A] are installed in the trans- mission case [B], press and insert them until they are bot-

tomed.

Special Tool - Bearing Driver Set 57001-1129

_• Install the following on the transmission case [A]. Shift Drum [B]

Pin [C]

Shift Drum Cam [D]

○^{Align the pin with the hole on the shift drum cam.}

_• Apply a non-permanent locking agent to the shift drum cam bolt [E] and tighten it.

Torque - Shift Drum Cam Bolt: 12 N·m (1.2 kgf·m, 106 in·lb)

_• Install the following as a set. Drive Shaft [F]

Output Shaft [G]

_• Install the forks as shown.

○^{Position the one [H] with shortest ears on the drive shaft}

and place the pin in the center groove in the shift drum.

○^{The two forks [J] on the output shaft are identical.}

_• Install the shift rods, noting the groove position.

○^{The rod [K] length of the output shaft side is shorter than}

the rod [L] length of the drive shaft side.

_• Apply molybdenum disulfide oil solution to the transmis- sion gears shown with X marks [M].

_• Be sure that the spacer [N] is on the output shaft.

Transmission Assy Installation

_• Assemble the transmission assy (see Transmission Assy Assembly).

_• Be sure that the dowel pins [A] are in position.

_• Apply grease to the O-ring [B] on the oil pipe.

_• Install the transmission assy on the crankcase.

_• Tighten the transmission case bolts.

Torque - Transmission Case Bolts: 20 N·m (2.0 kgf·m, 15

ft·lb)

_• Install the gear positioning lever (see External Shift Mech- anism Installation).

_• Install the shift rod plate.

Torque - Shift Rod Plate Bolt: 9.8 N·m (1.0 kgf·m, 87 in·lb)

_• Set the gear positioning lever to the neutral position [A].

_• Check that the drive and output shaft turn freely.

_• Install:

Pin [A]

Shift Drum Holder [B] Pin [C]

Neutral Switch Holder [D] Neutral Switch Holder Screw [E]

○^{Apply a non-permanent locking agent to the neutral switch}

holder screw and tighten it.

Torque - Neutral Switch Holder Screw: 4.9 N·m (0.50 kgf·m, 43 in·lb)

_• Apply grease to the O-ring [A] and install its position [B] on the output shaft.

_• Apply grease to the lip of the oil seal [C].

_• Install the collar [D].

Transmission Shaft Removal

_• Remove the transmission assy (see Transmission Assy Removal).

_• Remove:

Shift Rods [A]

Shift Forks [B]

Drive Shaft [C] and Output Shaft [D]

Transmission Shaft Installation

_• Be sure that the spacer [A] is on the output shaft [B].

_• Install the transmission assy on the crankcase (see Trans- mission Assy Installation).

_• Press in the oil seal [A] onto collar [B] so that the surface

of the oil seal is flush with the surface [C] of the crankcase.

○^{Apply oil to the outer circumference [D] of the oil seal so}

that it will go into place smoothly.

○^{Apply grease to the lip [E] of the oil seal.}

Transmission Shaft Disassembly

_• Remove the transmission shafts (see Transmission Shaft Removal).

_• Remove the circlips, disassemble the transmission

shafts.

Special Tool - Outside Circlip Pliers: 57001-144

_• The 5th gear [A] on the output shaft has three steel balls assembled into it for the positive neutral finder mecha-

nism. Remove the 5th gear.

○^{Set the output shaft in a vertical position holding the 3rd}

gear [B].

○^{Spin the 5th gear quickly [C] and pull it off upward.}

Transmission Shaft Assembly

_• Apply engine oil to the bushings, needle bearings and shafts.

_• Install the gear bushings [A] on the shaft with their holes

[B] aligned.

_• Replace any circlips removed with new ones.

_• Install the circlips [A] so that the opening [B] is aligned

with a spline groove [C].

_• The drive shaft gears can be recognized by size: the gear with the smallest diameter is 1st gear, and the largest one

is 6th gear. Be sure that all parts are put back in the cor- rect sequence and all circlips and washers are properly in place.

_• Install the 3rd/4th gear onto the drive shaft with their oil

holes aligned.

_• Install the 6th gear bushing onto the drive shaft with their oil holes aligned.

_• The output shaft gears can be recognized by size: the

gear with the largest diameter is 1st gear, and the small-

est one is 6th gear. Be sure that all parts are put back in the correct sequence and all circlips and washers are properly in place.

_• Install the 5th and 6th gears onto the output shaft with

their oil holes aligned.

_• Install the 3rd/4th gear bushings onto the output shaft with their oil holes aligned.

_• Fit the steel balls into the 5th gear holes in the output shaft, aligning three oil holes.

5th Gear [A] Output Shaft [B] Steel Balls [C] Oil Holes [D]

○^{After assembling the 5th gear with steel balls in place on}

the output shaft, check the ball-locking effect that the 5th

gear doesn’t come out of the output shaft when moving it up and down by hand.

_• Check that each gear spins or slides freely on the trans-

mission shafts without binding after assembly.

1. 1st Gear

2. 2nd Gear

3. 3rd Gear

4. 4th Gear

5. 5th Gear

6. 6th (Top) Gear

7. Ball Bearing

8. Bushing

9. Toothed Washer, 34 mm (1.34 in.)

10. Circlip

11. Bushing

12. Thrust Washer, 30 mm (1.18 in.)

13. Needle Bearing

14. Circlip

15. Oil Seal

16. Collar

17. Washer

18. Nut

19. O-ring

20. Bearing

21. Spacer, 39 mm (1.54 in.)

22. Positioning Ring

23. Washer, 40 mm (1.57 in.)

24. Bushing

25. Toothed Washer, 38 mm (1.50 in.) 26. Shim, 28 mm (1.10 in.)

27. Steel Ball

28. Circlip, 32.2 mm (1.268 in.)

29. Thrust Washer, 25 mm (0.98 in.)

Shift Drum and Fork Removal

_• Remove the transmission assy (see Transmission Assy Removal).

_• Remove the shift forks [A] and shift drum [B] (see Trans-

mission Assy Disassembly).

Shift Drum and Fork Installation

_• Refer to the Transmission Assy Assembly and Installa- tion.

Shift Drum Disassembly

_• Refer to the Transmission Assy Removal and Disassem- bly.

Shift Drum Assembly

_• Refer to the Transmission Assy Assembly and Installa- tion.

Shift Fork Bending

_• Visually inspect the shift forks, and replace any fork that is bent. A bent fork could cause difficulty in shifting, or allow

the transmission to jump out of gear when under power. 90° [A]

Shift Fork/Gear Groove Wear

_• Measure the thickness of the shift fork ears [A], and mea- sure the width [B] of the gear grooves.

If the thickness of a shift fork ear is less than the service limit, the shift fork must be replaced.

Shift Fork Ear Thickness

Standard: 5.9  6.0 mm (0.232  0.236 in.)

Service Limit: 5.8 mm (0.228 in.)

If the gear groove is worn over the service limit, the gear must be replaced.

Gear Groove Width

Standard: 6.05  6.15 mm (0.238  0.242 in.)

Service Limit: 6.25 mm (0.246 in.)

Shift Fork Guide Pin/Drum Groove Wear

_• Measure the diameter of each shift fork guide pin [A], and measure the width [B] of each shift drum groove.

If the guide pin on any shift fork is less than the service limit, the fork must be replaced.

Shift Fork Guide Pin Diameter

Standard: 6.9  7.0 mm (0.272  0.276 in.)

Service Limit: 6.8 mm (0.268 in.)

If any shift drum groove is worn over the service limit, the drum must be replaced.

Shift Drum Groove Width

Standard: 7.05  7.20 mm (0.278  0.283 in.)

Service Limit: 7.3 mm (0.287 in.)

Gear Dog and Gear Dog Hole Damage

_• Visually inspect the gear dogs [A] and gear dog holes [B]. Replace any damaged gears or gears with excessively

worn dogs or dog holes.