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ENGTRANSMISSION, SHIFT CAM AND SHIFT FORK
TRANSMISSION, SHIFT CAM AND SHIFT FORK
Extent of removal:1 Shift cam and shift fork removal2 Main axle and drive axle removal
Extent of removal Order Part name Q’ty Remarks
TRANSMISSION, SHIFTCAM
AND SHIFT FORK REMOVAL
Preparation for removal Engine Refer to “ENGINE REMOVAL” section.
Separate the crankcase. Refer to “CRANKCASE, CRANKSHAFT
AND BALANCER” section.
1 Shift fork guide bar 1 (short) 1
2 Shift fork guide bar 2 (long) 1
3 Shift cam 1
4 Shift fork 2 (C) 1
5 Shift fork 3 (R) 1
6 Shift fork 1 (L) 1
7 Main axle 1
Refer to “REMOVAL POINTS”.
8 Drive axle 1
9 Push rod 2 1
10 Washer 1
1
2
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ENGTRANSMISSION, SHIFT CAM AND SHIFT FORK
3. Install:
lPlain washer 1
lCirclip 2
NOTE:
lBe sure the circlip sharp-edged corner a is
positioned opposite side to the plain washer
and gear b.
lBe sure the circlip end c is positioned at
axle spline groove d.
New
4. Install:
lPush rod 2
On main axle.
NOTE:
Apply the engine oil on the push rod 2.
5. Install:
lWasher 1
On drive axle.
6. Install:
lMain axle
lDrive axle
Install these in the left crankcase at the
same time.
NOTE:
lApply the lithium soap base grease on the oil
seal lip.
lWhen installing the drive axle into the crank-
case, pay careful attention to the crankcase
oil seal lip.
Page 334 of 442
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ENGTRANSMISSION, SHIFT CAM AND SHIFT FORK
Shift cam and shift fork
1. Install:
lShift fork 1 (L) 1
lShift fork 2 (C) 2
lShift fork 3 (R) 3
NOTE:
lMesh the shift fork #1 (L) with the 2nd wheel
gear and #3 (R) with the 4th wheel gear on
the drive axle.
lMesh the shift fork #2 (C) with the 3rd pinion
gear on the main axle.
2. Install:
lShift cam 1
NOTE:
Apply the engine oil on the shift cam.
3. Install:
lShift fork guide bar 1 (short) 1
lShift fork guide bar 2 (long) 2
NOTE:
lApply the engine oil on the guide bars.
lBe sure the long bar is inserted into the shift
forks #1 and #3 and the short one into #2.
4. Check:
lShifter operation
lTransmission operation
Unsmooth operation ® Repair.
Page 336 of 442
5 - 1
CHAS
EC500000
CHASSIS
FRONT WHEEL AND FRONT BRAKE
Extent of removal:
1
Front wheel removal
2
Wheel bearing removal
3
Brake shoe plate assembly removal and disassembly
Extent of removal Order Part name Q’ty Remarks
Preparation for removal
FRONT WHEEL AND DRUM
BRAKE
Hold the machine by placing the
suitable stand under the engine.
1 Brake cable holder 1
2 Brake cable 1 Disconnect at the lever side, first.
3 Axle nut 1
4 Wheel axle 1
5 Front wheel 1
6 Collar set 1
7 Brake shoe plate assembly 1
8 Oil seal 1
9 Wheel bearing 2 Refer to “REMOVAL POINTS”.
10Spacer
1
WARNING
Support the machine securely so there is nodanger of it falling over.
2
3
1
FRONT WHEEL AND FRONT BRAKE
5
Page 350 of 442
5 - 8
CHAS
REAR WHEEL AND REAR BRAKE
Extent of removal:1 Rear wheel removal 2 Wheel bearing removal
3 Brake shoe plate assembly removal and disassembly
Extent of removal Order Part name Q’ty Remarks
Preparation for removalREAR WHEEL AND DRUM
BRAKE
Hold the machine by placing the
suitable stand under the engine.
1 Brake rod 1
2 Axle nut 1
3 Drive chain puller (right) 1
4 Wheel axle 1
5 Drive chain puller (left) 1
6 Drive chain 1
7 Rear wheel 1 Refer to “REMOVAL POINTS”.
8 Collar (right) 1
9 Brake shoe plate assembly 1
10Collar (left)
1
WARNING
Support the machine securely so there is nodanger of it falling over.
231
REAR WHEEL AND REAR BRAKE
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CHAS
EC550000
FRONT FORK
Extent of removal:1 Front fork removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removalFRONT FORK REMOVAL
Hold the machine by placing the
suitable stand under the engine.
Front wheel Refer to “FRONT WHEEL AND FRONT
BRAKE” section.
Handlebar Refer to “HANDLEBAR” section.
1 Cap 1
2 Pinch bolt (upper bracket) 1 Only loosening.
3 Cap bolt 1Loosen when disassembling the front fork.
4 Pinch bolt (lower bracket) 1 Only loosening.
5Front fork
1
WARNING
Support the machine securely so there is nodanger of it falling over.
1
FRONT FORK
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CHASHANDLEBAR
EC5B0000
HANDLEBAR
Extent of removal:1 Handlebar removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removalHANDLEBAR REMOVAL
Number plate
1 Clutch cable 1
2 Clutch lever 1
3 Engine stop switch 1
4 Front brake cable 1
5 Front brake lever 1
6 Grip cap (lower) 1
7 Grip cap (upper) 1
8 Throttle cable 1
9 Throttle grip assembly 1
10 Collar 1
11 Handlebar grip (left) 1 Refer to “REMOVAL POINTS”.
12 Handlebar holder 2
13 Handlebar 1
1
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CHAS
8. Install:
lEngine stop switch 1
lClutch lever holder 2
lBolts (clutch lever holder) 3
NOTE:
lThe engine stop switch and clutch lever
holder should be installed according to the
dimensions shown.
lPass the engine stop switch lead in the mid-
dle of the clutch lever holder.
T R..4 Nm (0.4 m · kg, 2.9 ft · lb)
9. Install:
lClutch cable 1
lClamp
NOTE:
Apply the lithium soap base grease on the
clutch cable end.
10. Adjust:
lClutch lever free play
Refer to “CLUTCH ADJUSTMENT”
section in the CHAPTER 3.
HANDLEBAR