Transmission Shaft Removal
Split the crankcase (see Crankcase Disassembly).
Pull out the shift rods [A] allowing the shift fork guide pins
to free from the shift drum [B].
Shift Forks [C]
Pull out the drive shaft [D] and output shaft [E] together
with their gears meshed.
Transmission Shaft Installation
Apply engine oil to the sliding portion of the transmission
shaft, gears, and ball bearings.
Install the drive shaft [A] and output shaft [B] in the right
crankcase half with their gears meshed.
Apply a small amount of engine oil to the shift fork fingers
and fit each shift fork into the groove of the proper gear.
Install the shift fork of the drive shaft with its mark [A]
facing the engine right side.
Install the shift forks of the output shaft with its marks [B]
facing the engine left side.
647 (Drive shaft)
648 (Output shaft)
Install the shift drum [A].
Fit each shift fork guide pin into the corresponding groove
in the shift drum.
Apply a small amount of engine oil to the shift rods [B] and
slide them into the shift forks.
Assembly the crankcase (see Crankcase Assembly).
Transmission Shaft Disassembly
Remove the transmission shafts (see Transmission Shaft
Remove the circlips, washers, collar and gears.
Special Tool - Outside Circlip Pliers: 57001-144
Do not reuse the removed circlips.