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. See Cylinder 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.
10. Remove neutral switch. See Neutral indicator switch.
11. Remove drum and forks. See Drum and forks.
Remove
Note: Input and output shaft assemblies separate once removed.
1. See Figure 5-20. Remove transmission assembly.
Install
1. See Figure 5-20. Install transmission.
- a. Mesh gears of input and output shaft assemblies.
- b. Install transmission as an assembly into right crankcase half.
Figure 5-20. Transmission Assembly
Disassemble
Input Shaft
1. See Figure 5-21. Remove gears (2-6) from input shaft.
Output Shaft
1. See Figure 5-22. Remove gears (1-8) from output shaft.
Assemble
Input Shaft
1. See Figure 5-21. Install gears (2-6) on input shaft.
Output Shaft
1. See Figure 5-22. Install gears (1-8) on output shaft.
- a. First gear (8) has one side that is machined. Place machined side toward fifth gear (6).
Figure 5-21. Input Shaft: 1. Restrictor plug; 2. Fifth gear (28 teeth); 3. Washer (25 mm ID); 4. Fourth (26 teeth)/Third (23 teeth) gear; 5. Sixth gear (30 teeth); 6. Second gear (19 teeth); 7. Washer (17 mm ID)
Figure 5-22. Output Shaft: 1. Second gear (38 teeth); 2. Washer (25 mm ID); 3. Sixth gear (27 teeth); 4. Third gear (34 teeth); 5. Fourth gear (31 teeth); 6. Fifth gear (28 teeth); 7. Washer (22 mm ID); 8. First gear (34 teeth); 9. Washer (17 mm ID)
Complete
1. Install drum and forks. See Drum and forks.
2. Join crankcase halves. See Crankcase assembly.
3. Install neutral switch. See Neutral indicator switch.
4. Install output pulley. See Output pulley
5. Install balancer shaft. See Removing and installing balancer.
6. Install cylinders. See Removing and installing cylinders.
7. Install cylinder heads. See Cylinder heads.
8. Install cylinder head covers. See Cylinder head covers.
9. Install clutch. See Removing and installing clutch.
10. Install starter. See Removing and installing starter.
11. Install engine. See Replace engine.