SHIFT SHAFT

Removing the shift shaft and stopper lever

Order

Job/Parts to remove

Q’ty

Remarks

 

Primary driven gear

 

Refer to CLUTCH.

1

Shift pedal

1

 

2

Shift shaft

1

 

3

Oil seal

1

 

4

Collar

1

 

5

Shift shaft spring

1

 

6

Roller

1

 

7

Shift guide

1

 

Removing the shift shaft and stopper lever

Order

Job/Parts to remove

Q’ty

Remarks

8

Shift lever assembly

1

 

9

Shift lever

1

 

10

Pawl

2

 

11

Pawl pin

2

 

12

Spring

2

 

13

Stopper lever

1

 

14

Stopper lever spring

1

 

15

Segment

1

 

REMOVING THE SEGMENT

1.Remove:

  • Segment bolt “1”

  • Segment “2”

Turn the segment counterclockwise until it stops and loosen the segment bolt.

If the segment gets an impact, the stopper lever may be damaged. Take care not to give an impact to it when removing the bolt.

CHECKING THE SHIFT SHAFT

1.Check:

  • Shift shaft “1”

    Bends/damage/wear → Replace.

  • Shift shaft spring “2”

    Damage/wear → Replace.

2.Check:

  • Shift guide “1”

  • Shift lever “2”

  • Pawl “3”

  • Pawl pin “4”

  • Spring “5”

    Wear/damage → Replace.

CHECKING THE STOPPER LEVER

1.Check:

  • Stopper lever “1”

    Wear/damage → Replace.

  • Stopper lever spring “2”

    Broken → Replace.

INSTALLING THE SHIFT SHAFT

1.Install:

  • Stopper lever spring “1”

  • Collar “2”

  • Stopper lever “3”

  • Bolt (stopper lever) “4”

  • Bolt (stopper lever)

    10 N·m (1.0 kgf·m, 7.4 lb·ft)

    LOCTITE®

2.Install:

  • Segment “1”

  • Segment bolt

  • Segment bolt

    30 N·m (3.0 kgf·m, 22 lb·ft)

  • Align the notch “a” on the segment with the pin “b” on the shift drum.

  • With the stopper lever pushed down, install the segment.

If the segment gets an impact, the stopper lever may be damaged. Take care not to give an impact to it when tightening the bolt.

3.Install:

  • Spring “1”

  • Pawl pin “2”

  • Pawl “3”

    (to the shift lever)

Apply the engine oil on the spring, pawl pin and pawl.

4.Install:

  • Shift lever assembly

    (to the shift guide)

5.Install:

  • Shift lever assembly “1”

  • Shift guide “2”

The shift lever assembly is installed at the same time as the shift guide.

6.Tighten:

  • Shift guide bolt “1”

  • Shift guide bolt

    10 N·m (1.0 kgf·m, 7.4 lb·ft)

    LOCTITE®

7.Install:

  • Roller “1”

  • Shift shaft spring “2” (to the shift shaft)

  • Collar “3” (to the shift shaft)

  • Shift shaft “4”

Apply the engine oil on the shift shaft.

8.Install:

  • Oil seal

9.Install:

  • Shift pedal “1”

  • Shift pedal bolt “2”

  • Shift pedal bolt

    12 N·m (1.2 kgf·m, 8.9 lb·ft)

Align the punch mark “a” on the shift shaft with the punch mark “b” in the shift pedal.