Set the these cover bolts [A] to the cover before cover
Install the cover with the shaft to the crankcase.
Torque - External Shift Mechanism Cover Bolts: 9.8 N·m
(1.0 kgf·m, 87 in·lb)
External Shift Mechanism Inspection
Examine the shift shaft [A] for any damage.
If the shaft is bent, straighten or replace it.
If the splines [B] are damaged, replace the shaft.
If the springs [C] are damaged in any way, replace them.
If the shift mechanism arm [D] is damaged in any way,
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: 29 N·m (3.0 kgf·m,
Check the gear set lever [B] and spring [C] for breaks or
If the lever or spring is damaged in any way, replace it.
Visually inspect the shift drum cam [D].
If it is badly worn or shows any damage, replace it.
Transmission Shaft and Shift Fork Removal
Split the crankcase (see Crankcase Splitting).
Shift Rod [A]
Shift Forks [B]
Take out the drive shaft [C] and output shaft [D] as a set.
Transmission Shaft and Shift Fork Installation
Apply engine oil to the transmission shafts and shift forks.
Install the drive shaft and output shaft as a set.
Install the shift forks [A] [B] so that the marks (031) [C] on
the shift fork for output shaft face the upward.
The two forks on the output shaft are identical.