Page 327 of 457
5-105
TRANSMISSIONENG
NOTE:
12 Nm (1.2 mkg, 8.7 ftlb)
10 Nm (1.0 mkg, 7.2 ftlb)
NOTE: 2. Measure:
drive axle runout
(with a centering device and dial gauge
1)
Out of specification Replace the drive
axle.
Drive axle runout limit
0.08 mm (0.0032 in)
3. Check:
transmission gears
Blue discoloration / pitting / wear Replace
the defective gear(s).
transmission gear dogs
Cracks / damage / rounded edges Replace
the defective gear(s).
INSTALLING THE TRANSMISSION
1. Install:
bearing
1
Make the seal side of bearing face to the outside
and install it close to the right end face of the
crankcase.
oil pipe
2
2. Install:
main axle assembly
1
bearing housing 2
LOCTITE
shift fork “C”
shift drum assembly
shift fork guide bar
shift fork guide bar retainer
LOCTITE
The embossed marks on the shift forks should
face towards the right side of the engine and
be in the following sequence: “R”, “C”, “L”.
Carefully position the shift forks so that they
are installed correctly into the transmission
gears.
Install shift fork “C” into the groove in the 3rd
and 4th pinion gear on the main axle.
ProCarManuals.com
Page 328 of 457
5-106
TRANSMISSIONENG
10 Nm (1.0 mkg, 7.2 ftlb)
NOTE:
NOTE: 3. Install:
shift fork “L”
1 and “R” 2
drive axle assembly 3
shift fork guide bar
shift fork guide bar retainer
4
LOCTITE
Install shift fork “L” into the groove in the 6th
wheel gear and shift fork “R” into the groove in
the 5th wheel gear on the drive axle.
Make sure that the drive axle bearing circlip
a
is inserted into the grooves in the upper crank-
case.
4. Check:
transmission
Rough movement Repair.
Oil each gear, shaft, and bearing thoroughly.
ProCarManuals.com
Page 451 of 457
9-3
FAULTY GEAR SHIFTING / FAULTY CLUTCH
TRBL
SHTG
JUMPS OUT OF GEAR
Shift shaft
Incorrect shift pedal position
Improperly returned stopper lever
Shift forks
Worn shift fork
Shift drum
Incorrect axial play
Worn shift drum groove
Transmission
Worn gear dog
CLUTCH DRAGS
Clutch
Unevenly tensioned clutch springs
Warped pressure plate
Bent clutch plate
Swollen friction plate
Bent clutch pull rod
Broken clutch boss
Burnt primary driven gear bushing
Match marks not aligned
Engine oil
Incorrect oil level
Incorrect oil viscosity (high)
Deteriorated oil
EAS00850
FAULTY GEAR SHIFTING
SHIFTING IS DIFFICULT
Refer to “CLUTCH DRAGS”.
SHIFT PEDAL DOES NOT MOVE
Shift shaft
Improperly adjusted shift rod
Bent shift shaft.
Shift drum and shift forks
Foreign object in a shift drum groove
Seized shift fork
Bent shift fork guide bar
Transmission
Seized transmission gear
Foreign object between transmission gears
Improperly assembled transmission
EAS00851
FAULTY CLUTCH
CLUTCH SLIPS
Clutch
Improperly assembled clutch
Improperly adjusted clutch cable
Loose or fatigued clutch spring
Worn friction plate
Worn clutch plate
Engine oil
Incorrect oil level
Incorrect oil viscosity (low)
Deteriorated oil
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