Shift Fork Bending Inspection
Visually inspect the shift forks, and replace any fork that is
bent. A bent fork may cause difficulty in shifting, or allow
the transmission to jump out of gear when under power.
Shift Fork/Gear Groove Wear Inspection
Measure the thickness [A] of the shift fork ears, and mea-
sure the width [B] of the gear grooves (with which the fork
Shift Fork Ear Thickness
Gear Groove Width
If the thickness of a shift fork ear is less than the service
limit, the shift fork must be replaced.
If the gear groove is worn exceeding the service limit, the
gear must be replaced.
Shift Fork Guide Pin/Shift Drum Groove Wear
Measure the diameter of each shift fork guide pin [A], and
measure the width [B] of each shift drum groove.
Shift Fork Guide Pin Diameter
Shift Drum Groove Width
If the guide pin on any shift fork is less than the service
limit, the fork must be replaced.
If any shift drum groove is worn exceeding the service
limit, the drum must be replaced.
Gear Damage Inspection
Visually inspect the gear dogs [A] and gear dog holes [B].
Replace any damaged gears or gears with excessively
worn dogs or dog holes.
Visually inspect the gear teeth [C] on the transmission
Replace lightly damaged gear teeth with an oilstone. The
gear must be replaced if the teeth are badly damaged.
When gear is repaired or replaced, the driving gear should
also be inspected and repaired or replaced if necessary.
4.9 ∼ 5.0 mm (0.193 ∼ 0.197 in.)
4.8 mm (0.19 in.)
5.05 ∼ 5.15 mm (0.199 ∼ 0.203 in.)
5.2 mm (0.20 in.)
5.9 ∼ 6.0 mm (0.232 ∼ 0.236 in.)
5.8 mm (0.228 in.)
6.05 ∼ 6.20 mm (0.238 ∼ 0.244 in.)
6.3 mm (0.25 in.)