TRANSMISSION DISASSEMBLY
Separate the crankcase halves (page 13-10).
Temporarily install the right crankcase.
Place the right crankcase facing down and separate the right and left crankcase halves.
Remove the shift fork shafts.
Remove the shift fork guide pins from the shift drum grooves and remove the shift drum.
Remove the shift forks.
Remove the mainshaft and countershaft as an
assembly from the right crankcase.
Disassemble the transmission:
• Keep track of the disassembled parts (gears, bushings, washers, and rings) by sliding them onto a tool or a piece of wire.
• Do not remove the snap rings over the shafts. Expand the snap ring ends and slide the snap ring off the shaft, along with the gear behind it.
GEAR
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Check the gear dogs, dog holders and teeth for damage or excessive wear.
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Measure the I. D. of each gear.
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SERVICE LIMITS:
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BUSHING
Check the bushings for damage or excessive wear. Measure the O. D. of each bushing.
SERVICE LIMITS:
M4: 27.94 mm (1.100 in)
C2: 29.95 mm (1.179 in)
After 07:
M5: 27.94 mm (1.100 in)
C3: 27.95 mm (1.100 in)
Measure the I. D. of each bushing.
SERVICE LIMITS:
C2: 27.04 mm (1.065 in)
After 07:
M5/C3: 25.04 mm (0.9858 in)
Measure the gear to bushing clearance.
SERVICE LIMITS:
M4: 0.11 mm (0.004 in)
C2: 0.12 mm (0.005 in)
After 07:
M5/C3: 0.12 mm (0.005 in)
NEEDLE BEARING
Check the C1 gear needle bearing for damage. Replace it if necessary.
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MAINSHAFT/COUNTERSHAFT
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M5
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Check the spline grooves and sliding surfaces for damage or abnormal wear.
Measure the O. D. of the mainshaft and countershaft at the gear and bushing sliding areas.
SERVICE LIMITS:
Mainshaft: M5: 24.94 mm (0.982 in)
Countershaft: C1 bearing: 18.94 mm (0.746 in)
C2 bushing: 26.94 mm (1.061 in)
C3: 24.96 mm (0.983 in)
'05- '07: Measure the gear to shaft clearance.
SERVICE LIMITS:M5: 0.13 mm (0.005 in) C2 BUSHING СЗ C1 BEARING
C3: 0.082 mm (0.0032 in)
Measure the bushing to shaft clearance.
SERVICE LIMITS:
C2: 0.12 mm (0.005 in)
After '07:
M5/C3: 0.12 mm (0.005 in)
SHIFT FORK
Check the shift fork for abnormal wear or deformation.
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Measure the shift fork I. D. and claw thickness.
SERVICE LIMITS:
I. D.: Center: 11.011 mm (0.4335 in)
Right and left: 12.070 mm (0.4752 in)
Claw thickness: 4.8 mm (0.19 in)
SHIFT FORK SHAFT
Check the shift fork shaft for abnormal wear or deformation.
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Measure the shift fork shaft O. D.
SERVICE LIMITS:
Center: 10.969 mm (0.4318 in)
Right and left: 11.950 mm (0.4705 in)
SHIFT DRUM
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SHIFT DRUM |
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Inspect the shift drum for scoring, scratches or evidence of insufficient lubrication.
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Check the shift drum grooves for abnormal wear or damage.
TRANSMISSION BEARING
Turn the inner race of each bearing with your finger. The bearings should turn smoothly and quietly.
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Also check that the bearing outer race fits tightly in the crankcase.
Replace any bearing if the inner race does not turn smoothly and quietly, or if the outer race fits loosely in the crankcase (page 13-18).
