Prepare
1. Remove engine. See Replace engine.
2. Remove starter. See Removing and installing starter.
3. Remove clutch. See Removing and installing clutch.
4. Remove cylinder head covers. SeeCylinder head covers.
5. Remove cylinder heads. See Cylinder heads.
6. Remove cylinders. See Removing and installing cylinders.
7. Remove balancer shaft. See Removing and installing balancer.
8. Remove output pulley. See Output pulley
9. Separate crankcase. See Crankcase assembly.
Remove
1. See Figure 5-16. Remove shafts (4).
2. Remove shift drum (3).
3. Remove forks (1, 2, 5).
Install
1. See Figure 5-16. Install forks (1,2, 5).
- a. See Figure 5-17. Identify forks using mark (1). Refer to Table 5-7.
- b. Slider (2) for each fork faces shift drum once installed.
2. See Figure 5-16. Install shift drum.
3. Install shafts (4).
Table 5-7. Fork Identification
| DESCRIPTION | MARKING |
| First/fourth fork | R |
| Second/third fork | L |
| Fifth/sixth fork | C |
Figure 5-16. Shift Drum and Forks: 1. First/fourth fork; 2. Second/third fork; 3. Shift drum; 4. Shaft (2); 5. Fifth/sixth fork
Figure 5-17. Shift Fork: 1. Position mark; 2. Slider
Disassemble
1. See Figure 5-18. Remove index pin (1).
2. Remove neutral switch contact assembly.
- a. Remove screw (6).
- b. Remove contact plate (5), contact pin (4) and spring (3).
Assemble
| FASTENER | TORQUE VALUE | |
| Shift drum contact assembly screw | 5.0-7.0 Nm | 45-62 in·lbs |
1. See Figure 5-18. Install index pin (1).
Note: See Figure 5-19 for assembled view of neutral switch contact assembly.
2. See Figure 5-18. Install neutral switch contact assembly.
- a. Install spring (3).
- b. Install contact pin (4) and contact plate (5).
- c. Install screw (6). Tighten to 5.0-7.0 Nm (45-62 in·lbs).
Figure 5-18. Shift Drum Assembly: 1. Index pin; 2. Shift drum; 3. Spring; 4. Contact pin; 5. Contact plate; 6. Screw
Figure 5-19. Neutral Switch Contact Assembly
Complete
1. Join crankcase halves. See Crankcase assembly.
2. Install output pulley. See Output pulley
3. Install balancer shaft. See Removing and installing balancer.
4. Install cylinders. See Removing and installing cylinders.
5. Install cylinder heads. See Cylinder heads.
6. Install cylinder head covers. See Cylinder head covers.
7. Install clutch. See Removing and installing clutch.
8. Install starter. See Removing and installing starter.
9. Install engine. See Replace engine.