3. Slide the end of the shift shaft into the crankcase
boss (B,
Figure 6
) until the assembly bottoms. Note
the following:
a. The arms of the shift shaft spring (C,
Figure
4
) must straddle the post in the crankcase.
b. When the shift arm is released, the shift pawls
must engage the pins on the shift drum as
shown in A,
Figure 7
.
c. The roller (D,
Figure 4
) on the stopper lever
must engage the detent on the shift cam.
4. Pull the arm of the stopper lever spring (B,
Fig-
ure 7
) and seat it on the forward side of the crank-
case boss (C).
Disassembly/Assembly
NOTE
Replace any removed E clip. An
E clip should not be reused.
1. Remove the washer from each end of the shift
shaft.
2. Remove the inboard E-clip and the washer. Dis-
card the E-clip.
3. Slide the stopper lever and stopper lever spring
from the shift shaft.
4. Remove the washer and the middle E-clip.
6. Slide the shift shaft spring and its collar from the
assembly.
7. If necessary, remove and discard the remaining
E-clip.
8. Assembly is the reverse of removal. Note the
following:
a. Use new E-clips. Make sure each clip com-
pletely engages its groove in the shift shaft.
b. The arms of the shift shaft spring must strad-
dle the tab (C,
Figure 5
) on the shift shaft.
c. The hook on the stopper lever spring must sit
in the cutout on the stopper lever
Inspection
Replace any part that is worn or damaged.
1. Inspect the shift shaft for bends or damage.
2. Inspect the shift arm for bends or damage. Pay
particular attention to the shift pawls.
3. Check the shift arm spring, the shift shaft spring
and the stopper lever spring for cracks or signs of
fatigue. Replace any spring as necessary.
4. Check the operation of the roller on the stopper
lever. It should move smoothly.
5. Inspect the stopper lever for bends or other signs
of damage.
INTERNAL SHIFT MECHANISM
Removal/Installation
Remove and install the internal shift mechanism
as described in
Crankcase Disassembly
and
Crank
case Assembly
in Chapter Five.
Inspection
Refer to
Figure 8
.
1. Inspect each shift fork for signs of wear or crack-
ing. Examine each fork at the points where their fin-
gers (A,
Figure 9
) contact the gears and where the
guide post (B) contacts the shift drum. These sur-
faces should be smooth with no signs of wear or
damage.
2. Make sure each fork slides smoothly on the shaft
(
Figure 10
). If there is any binding, replace the fork
shaft and related shift fork(s).
3. Roll the shift fork shaft along a surface plate or
piece of glass. Any clicking sounds indicate that the
shaft is bent and must be replaced.
4. Inspect the grooves in the shift drum (A,
Figure
11
) for wear or roughness. Replace the shift drum if
any groove is worn.
5. Inspect the shift drum journal (B,
Figure 11
) for
wear or discoloration.
6. Spin the drum bearing (C,
Figure 11
), and check
for excessive play or roughness.
7. Inspect the neutral post (A,
Figure 12
) for wear
or damage.
188
CHAPTER SEVEN
7
