Transmission Assembly - Honda XL200 2001 Shop Manual

XL2 0 0
Check the shift fork for any wear, bending or damage.
Measure the shift fork I.D.
SERVICE LIMITS: 12.05 mm (0.474 in)
Measure the shift fork claw thichness.
SERVICE LIMITS: 4.50 mm (0.177 in)
Check the shift fork shaft for bend, worn or damaged
Measure the shift fork shaft O.D.
SERVICE LIMITS: 11.96 mm (0.471 in)
Inspect the shift drum grooves.
Replace the shift drum if the grooves are damaged or
excessively worn.
Turn the inner race of each bearing with your finger.
The bearings should be turn smoothly and quietly.
Also check that the bearing outer race fits tightly in the
crankcase.
Remove and discard the bearings if the races do not turn
smoothly, quietly, or if they fit loosely in the crankcase (page
10-9).
ASSEMBLY
NOTE
• Coat each gear, bushing shift fork, shift fork shaft, shift
drum, shift drum journal, mainshaft and countershaft with
transmission oil.
• Install the snap ring with its chamfered side facing the gear.
Assemble the mainshaft and countershaft.
CRANKSHAFT/TRANSMISSION
FORK
SHAFT
DRUM
(1) BEARING
MAINSHAFT
COUNTERSHAFT
1 0 -5