Removal
XL600V-H to R (1987 to 1995) models
1. Separate the crankcase halves (Section 23). Remove the crankshaft (see Section 27) - though not essential, working with it in place restricts access and makes the procedure fiddly.
2. The transmission shafts must be removed along with the selector drum and forks as a complete assembly. Note that each selector fork is marked for identification. The left-hand fork is marked with an 'L'. the middle fork is marked with a 'O', and the right-hand fork is marked with an 'R', all of which must face the right-hand crankcase half (see illustration 29.7). If no letters are visible, mark them youtself using a felt pen. The right and left-hand forks fit into the output shaft and the centre fork fits into the input shaft. At this point make a careful note of where each transmission shaft is positioned in relation to the selector drum and the fork assembly - the assembly must be removed an installed as one, and it is easy to get confused when assembling them together on the work bench before installation.
3. Grasp the input shaft and output shaft and the selector drum and forks and withdraw them from the crankcase as an assembly, noting their relative positions and how they fit together. Separate the selector drum, forks and transmission shafts, noting how the guide pin on each fork locates in its groove in the drum, and how each fork engages in the groove of its pinion.
4. Check whether the thrust washer on the left-hand end of each shaft is on the shaft or in the crankcase (probably lying loose on the bearing). Fit the washer onto the end of each shaft as a reminder for installation. Also note the thrust washer on the right-hand end of the output shaft.
5. If necessary, the transmission shafts can be disassembled and inspected for wear or damage (see Section 31).
All other models
6. Separate the crankcase halves (Section 23). Remove the crankshaft (see Section 27) - though not essential, working with it in place restricts access and makes the procedure more fiddly.
7. Remove the selector drum and forks (see Section 29).
8. Grasp the input shaft and output shaft and withdraw them from the crankcase as an assembly, noting their relative positions and how they fit together (see illustration) Separate the shafts. On XL600V models check whether the thrust washer on the lefthand end of each shaft, and on XI650V models the thrust washer on the left-hand end of the input shaft, is on the shaft or In the crankcase (probably lying loose on the bearing). Fit the washer onto the end of each shaft as a reminder for installation. On all models also note the thrust washer on the right-hand end of the output shaft.
30.8. Grasp the shafts and lift them out of the crankcase
9. If necessary, the transmission shafts can be disassembled and inspected for wear or damage (see Section 31).
Installation
XL600V-H to R (1987 to 1995) models
10. The transmission shafts must be installed along with the selector drum and forks as a complete assembly. To achieve this without the entire assembly falling apart as It is installed, it is advisable to obtain some cable ties so the shafts and selector forks can be strapped together. Support the left-hand half of the crankcase on wooden blocks so the end of the transmission output shaft does not contact the work surface as it is Installed.
11. Make sure that the thrust washer is installed on the left-hand end of each shaft (see illustrations 31.28b and 31.51d) Apply a smear of grease to the inner face of each washer to make them stick to their adjacent pinions and so prevent them dropping off as the shafts arc installed (see illustration 30.17), Also make sure that the thrust washer is installed on the right-hand end of the output shaft (see illustration 31.55d).
12. Lay the input shaft and output shaft side by side on the bench so that the pinions for each gear mesh together (see illustration 30.18). Make sure that the shafts are the correct way round, in which case the smallest pinion on the input shaft meshes with the largest pinion on the output shaft.
13. Fit the selector fork assembly onto the transmission shafts, locating each fork into the groove in its pinion, and making sure their identification marks are positioned as described in Step 2 Also make sure that the fork assembly is positioned correctly in relation to each shaft as noted on removal.
14. Engage the selector drum with the forks, locating their guide pins in the selector drum tracks, again making sure everything is correctly positioned - the right-hand end of the selector drum carries the bearing, so the selector fork marked 'R' must be engaged in the groove nearest the bearing, and at the same end of the assembly as the smallest pinion on the input shaft and the largest pinion on the output shaft. If you intend to use cable ties to hold the assembly together, fit them now.
15. Grasp the input shaft and output shaft and the selector drum and forks and install them into the left-hand crankcase, making sure that both input shaft and output shaft ends engage in their bearings and the selector fork shaft end and the selector drum journal engage in their holes in the crankcase. Make sure the thrust washers do not drop off the ends of the shafts as they are installed. If cable ties were used, cut them and slip them out of position.
16. Install the crankshaft (see Section 27). Reassemble the crankcase halves (see Section 23).
All other models
17. Support the left-hand half of the crankcase on wooden blocks so the end of the transmission output shaft does not contact the work surface as it is installed. On XL600V models make sure that the thrust washer is installed on the left-hand end of each shaft, and on XL650V models that one is installed on the left-hand end of the input shaft (see illustrations 31.28b and 31.51d) Apply a smear of grease to the inner face of each washer to make them stick to their adjacent pinions and so prevent them dropping off as the shafts are installed (see illustration). On all models make sure that the thrust washer is installed on the right-hand end of the output shaft (see illustration 31.55d).
30.17. Apply grease to each thrust washer to hold it in place
18. Lay the input shaft and output shaft side by side on the bench so that the pinions for each gear mesh together (see illustration). Make sure that the shafts are the correct way round, in which case the smallest pinion on the input shaft meshes with the largest pinion on the output shaft.
30.18. Position the shafts side by side so the relative pinions mesh
19. Grasp the input shaft and output shaft and install them into the left-hand crankcase, making sure that both ends engage in their bearings (see illustration 30.8).
20. Install the selector drum and forks (see Section 29).
21. Install the crankshaft if removed (see Section 27). Join the crankcase halves (Section 23).