Apply high temperature grease to the seal lips.
Insert the shift shaft into the cover [A], and then fit the shift
mechanism arm [B] to the shift drum [C].
Tighten the cover bolts.
Torque - External Shift Mechanism Cover Bolts: 11 N·m
(1.1 kgf·m. 95 in·lb)
Engine Oil Level (see Engine Oil Level Inspection in the
Engine Lubrication System chapter)
Drive Chain Slack (see Drive Chain Slack Inspection in
the Final Drive chapter)
External Shift Mechanism Inspection
Examine the shift shaft for any damage.
Check the shift shaft for bending or damage to the splines
If the shaft is bent, straighten or replace it. If the splines
are damaged, replace the shaft.
Check the return spring [B] and arm spring [C] for breaks
If the springs are damaged in any way, replace them.
Check the shift mechanism arm [D] for distortion.
If the shift mechanism arm is damaged in any way, re-
place the arm.
Check that 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 - Return Spring Pin: 20 N·m (2.0 kgf·m, 14.5 ft·lb)
Check the gear positioning levers [B], and their springs
[C] for break or distortion.
If the levers or springs are damaged in any way, replace
Visually inspect the shift drum cam [D] and pin plate [E].
If they are badly worn or if they show any damage, replace
Transmission Shaft Removal
Remove the engine (see Engine Removal in the Engine
Split the crankcase (see Crankcase Splitting).
Take out the output shaft assembly.
Lift up the drive shaft assembly, and pull the shaft assem-
bly out of the clutch housing. Leave the clutch housing
and primary chain in place.