Honda TRX400EX FOURTRAX 1999, Service Manual

Page: 150 / 263

. .
SHIFT
FORK
Check the shift fork guide pins for abnormal wear or
damage.
Measure the shift fork
SERVICE LIMIT 13.05 mm (0.514 in)
Measure the shift fork claw thickness.
SERVICE LIMIT 5.5
m m (0.22
in)
SHIFT FORK SHAFT
Check the shift fork shaft for damage or bending
Measure the shift fork shaft O.D.
SERVICE LIMIT (0.508 in)
GEARSHIFT
SPINDLE
Check the gearshift plate for wear or damage.
Check the return spring and reset spring for fatigue
or damage.
ASSEMBLY
Clean
all
parts in solvent and dry them thoroughly.
Apply molybdenum oil solution to the gear teeth,
sliding surface, shifter grooves and bushings.
Assemble the mainshaft and countershaft.
NOTE:
Always install the thrust washer and snap ring
with the chamfered (rolled) edge facing away from
the thrust load.
Install the snap ring
so that its end gap aligns with
the groove in the splines.
Make sure that the snap ring is fully seated in the
shaft groove after installing it.
CORRECT INCORRECT
SNAP
RING
11-6