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3. 5 UPPER AND
LOWER
CRANKCA
SE
55
P.
Gear
Shift
Disassdmbly
l
.
Remove the gear shift spindle in accordance
w
ith
sectio
n
3.
5.
C.
2.
Separate
the
upper and
low
er crankcases
in
accordance with section
3.
5.
C.
3.
Disassemble
the transmission
gears.
4.
Loosen the 6 mm hex. bolt
and
disasse.'nble
the neutral stopper and
shift
drum
stopper,
fol-
lowed
by
unscrewing the
6
mm
cross screw
and
removing the bearing set
plate
.
5.
Remo ve the shi
f t
fork guide pin clip and then
pull
out the guide
pin.
(Fig. 3. 115)
6.
Remove the gear
shift
drum
by
lightly tapping
the case on the
side
of the neutral switch moun-
ting.
Q.
Gear Shift Inspection
1.
Gea
r
shift fork
It em
Standard
value
!
Serviceable
limit
Insid
e
Dia.
fl
.3385-1.
33
9
inl
34.
l mm
11.3425
inl
--·
I
34.0-34.02
5
mm
I
Rep
lace
if
aver
'Left
I
4.93
-
5.0
mm
·
·
Replace if
under
End
I
Right
\1
0.
194 1-0
.
l 968
__
inl
_
4.6
mm
10.181
in!
thickness
C
5
.93-
6.0
mm
I
R ep
lace
if
under
I
enter
I
!0.233
4-0.23
6
inl
I
s:
6 mm
10.22
05
inl
Bend
in
fork
endl
With in
0.
1
mm
I
Replace
if
ov
er
(le
ft,
r
ight)
I
10.004
in)
I
0.8
mm
(0.03
1
inl
2.
Gear
shift drum guide groo
ves
It
em
Standard value
I
Serviceable
limit
-
-
--
-- -·--
-
--'
-
-
--
--1
·-1
6.05-
6.
15
mm
I
Replace
if
over
Gr
oove
width
10.238
-0.242
in)
6.5
mm
10.256
inl
I
R.
Gear Shift Reassembly
l.
Assemble
the
gear shift drum into
the
upper
case.
At this time, .make sure that the location
of the shift fork are in their respect ive position
(gear
shift
forks ore stamped in the center with
"R"
or
"L"
to identif
y
the right and
left
respec-
tjvely).
NOT
E:
When
assembly
ing the gear
shift
drum,
exercise
care not to damage the oil seal press fitted into
the
crankcase.
2.
Install the shift fork guide pin
into
the shift
fork and
lock
wi th a clip.
3.
Reinstall the bearing set plate using the
two
6
mm
cross screws, and also install the neutral
stopper and shift drum stopper.
4.
Reinstall the
transmission
gear
assembly.
Fig. 3. 115
Removing
the
gear shift drum
CD
Bearing set plate
®
Gear
shift drum
®
Shi
ft dr um
neutral stopper
©
Shift
drum
stopper
Fig.
3.
116
Measnring
fork end bending
CD
biol
gauge
®
Gear
shift f
o
rk
@
V-block
UP
PER
C
ASf
LOWER
CA
SE.
f ig
.
3. 117
Sectional view
of gear shift
drum and
fork
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