7-12 ENGINE BOTTOM ENDITRANSMISSION

• To install the shift forks and shift drum, see the

Transmission Shift Drum and Fork Installation Notes.

Transmission Shaft Removal

'Split the crankcase (see Crankcase Splitting).
Transmission Shaft Disassemb/y Notes
'Pull off the shift rod, and disengage the shift fork
guide pins from the shift drum grooves. 'Using circlip pliers (special tool: 57001-144) to re-
'Remove the shift drum. move the circlips, disassemble the transmission
'Remove the shift forks from the transmission gears.
• Take out the drive shaft and output shaft together,
with their gears meshed.
Transmission Shaft Assembly Notes
'Assembly is the reverse of removal.
•Apply transmission oil liberally to the
D transmission shaft, gears and bearings.
c 'Replace any circiips that were removed with new
ones.

OAlways install circliós so that the opening is

aligned with a spline groove, and install toothed
washers so that the teeth are not aiigned with the
circlip open-ing. To install a circlip without
damage, first fit the circlip onto the shaft
expanding it just enough to instan ite and then
use a suitable gear to push the circlip into place.

Circlip and Toothed Washer Installation

A. Shift Rods D. Output Shaft

B. Shift Forks E. Shift Drum 4

C. Drive Shaft

Transmission Shaft Installation Notes

•lnstallation is the reverse of removal.
'Hold the drive shaft and output shaft together, with
their gears meshed, and fit them into the right
crankcase half.
1. Teeth of Toothed Washer 4. Opening of Circiip
2. Toothed Washer
5. Cir
3. Groove of Shaft
6. Sh

'The drive shaft gears can be identified by size; the

smallest diameter gear is 1 st gear, and the largest is
6th. Be sure that all parts are put back in the correct
sequence, facing the proper direction, and that all
circlips and the washer are properly in place.

A. Drive Shaft B. Output Shaft