Shift Drum and Fork Removal
Remove the transmission assy (see Transmission Assy
Remove the shift forks [A] and shift drum [B] (see Trans-
mission Assy Disassembly).
Shift Drum and Fork Installation
Refer to Transmission Assy Assembly and Installation.
Shift Drum Disassembly
Refer to Transmission Assy Removal and Disassembly.
Shift Drum Assembly
Refer to Transmission Assembly and Installation.
Shift Fork Bending
Visually inspect the shift forks, and replace any fork that is
bent. A bent fork could cause difficulty in shifting, or allow
the transmission to jump out of gear when under power.
Shift Fork/Gear Groove Wear
Measure the thickness of the shift fork ears [A], and mea-
sure the width [B] of the gear grooves.
If the thickness of a shift fork ear is less than the service
limit, the shift fork must be replaced.
Shift Fork Ear Thickness
5.9 ∼ 6.0 mm (0.232 ∼ 0.236 in.)
Service Limit: 5.8 mm (0.228 in.)
If the gear groove is worn over the service limit, the gear
must be replaced.
Gear Groove Width
6.05 ∼ 6.15 mm (0.238 ∼ 0.242 in.)
Service Limit: 6.25 mm (0.246 in.)