External Shift Mechanism Installation
Install the gear set lever [A] and the spring [B] in the
crankcase and tighten the bolt [C].
Torque - Gear Set Lever Bolt: 11 N·m (1.1 kgf·m, 97 in·lb)
Install the shift mechanism arm assy. Be sure to install
the washer onto the shift shaft.
Install the front gear case (see Final Drive chapter).
Install the front shift lever and the rear shift lever.
Install the rear shift lever [A] on the shift shaft so that the
punched mark on the shaft is aligned [B] with the slot of
the rear shift lever.
Loosen the locknuts [C] and turn the shift rod [D] so that
the outside length [E] of the locknuts is 112 ±1 mm (4.41
The rear locknut has left-hand threads.
Torque - Shift Rod Locknuts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
Rear Shift Lever Clamp Bolt: 12 N·m (1.2 kgf·m,
Install the clutch hose grommet to the clamp on front gear
Install the engine (see Engine Removal/Installation)
External Shift Mechanism Inspection
Examine the shift shaft [A] for any damage.
If the shaft is bent, straighten or replace it.
If the serrations [B] are damaged, replace the shaft.
If the springs [C] [D] are damaged in any way, replace
If the shift mechanism arm [E] is damaged in any way,
replace the arm.
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: 39 N·m (4.0 kgf·m,
Check the gear set lever [B], and its spring [C] for breaks
If the lever or spring is damaged in any way, replace it.
Visually inspect the shift drum pins, pin holder, and pin
If they are badly worn or if they show any damage, replace