Check the return spring pin [A] is not loose.
If it is loose, unscrew it, apply a non-permanent locking
agent to the threads, and tighten it.
Torque - Shift Shaft Return Spring Pin: 28 N·m (2.9 kgf·m,
Check the gear positioning lever [B] and its spring for
breaks or distortion.
If the lever or spring are damaged in any way, replace
Visually inspect the shift drum cam [C].
If they are badly worn or if they show any damage, replace
Transmission Assy Removal
Engine Sprocket (see Engine Sprocket Removal in the
Final Drive chapter)
Gear Position Switch (see Gear Position Switch Re-
moval in the Electrical System chapter)
Clutch (see Clutch Removal in the Clutch chapter)
Shift Shaft Assembly (see External Shift Mechanism Re-
Transmission Case Bolts [A]
If the transmission assy is to be disassembed, remove the
Gear Positioning Lever Bolt [B]
Gear Positioning Lever [C], Spring and Collar
Pull the transmission assy [D] out of the crankcase.
Transmission Assy Disassembly
Remove the transmission assy (see Transmission Assy
Remove the following from the transmission case [A].
Shift Rods [B]
Shift Forks [C]
Drive Shaft [D]
Output Shaft [E]