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When installing the input shaft copper
bushing, align its oil hole with that ofthe
shaft (Figure 37).
The assembly sequence for the output shaft
(Figure 38) is 2nd gear (flat side toward
bearing), washer, circlip, 6th gear (dogs toward
2nd gear), circlip, splined washer, bushing
(chamfered side toward 6th gear), 4th gear
(recessed side toward 6th gear), washer, 3rd
gear (flat side toward 4th gear), washer, circlip,
5th gear (grooved side toward 3rd gear), 1st
gear (flat side away from 5th gear), washer,
needle bearing, circlip, outer race.
When installing the output shaft 5th
gear, do not grease the steel balls to hold
them in place. These balls must be able
to move freely. Insert the balls in the
holes with a smaller outer diameter
(Figure 39),
not in the large diameter set
of holes.
4. Install the gear sets in the upper crankcase
half, meshing the shift fork fingers with the gear
grooves (Figure 40). Rotate the bearings until
the dowel pins seat a n d make sure the
alignment rings are fully seated in the bearing
and case grooves.
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