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INSPECTION
GEARS
Check the gear dogs, dog holes and teeth for damage of
excessive wear.
Measure the I.D. of each gear.
SERVICE LIMIT:
M4:
20.05 mm (0.789 in)
M5:
17.05 mm (0.671 in)
C1:
20.55 mm (0.809 in)
C2:
23.07 mm (0.908 in)
C3:
20.07 mm (0.790 in)
BUSHING
Check the bushings for wear or damage.
Measure O.D. of each bushing.
SERVICE LIMIT:
C1:
20.41 mm (0.804 in)
C2
22.95 mm (0.904 in)
Calculate the gear-to-bushing clearance.
SERVICE LIMIT:
C1:
0.10 mm (0.004in)
C2:
0.10 mm (0.004 in)
Measure I.D of each bushing.
C1:
17.04 mm (0.6.71 in)
C2:
20.07 mm (0.790 in)
MAINSHAFT/COUNTERSHAFT
Check the spine grooves and sliding surfaces for abnormal
wear or damage.
Measure the O.D of the mainshaft and countershaft at gear
and bushing sliding areas.
SERVICE LIMIT:
Mainshaft
(at M4 gear bushing):
19.94 mm (0.785 in)
(at M5 gear bushing):
16.93 mm (0.666 in)
Countershaft
(at C1 gear bushing):
16.93 mm (0.667 in)
(at C2 gear bushing):
19.94 mm (0.785 in)
Calculate the bushing-to-shaft clearance.
SERVICE LIMIT:
C1:
0.10 mm (0.004 in)
C2:
0.20 mm (0.008 in)
SHIFT DRUM
Inspect the shift drum end for scoring, scratches, or
evidence of sufficient lubrication.
Check the shift drum grooves for abnormal wear or
damage.
CRANKCASE/TRANSMISSION/KICKSTARTER
M5
C2
SHIFT DRUM
M4
C3
C1
11-7
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Troubleshooting
