1. Check the fork and rod for damage. Replace if it is damaged.
2. Gearshift mechanism
Repair or replace the gearshift mechanism if excessively worn, bent or defective in any way.
3. Inspect the clearance between 2nd driven gear and coupling sleeve. If any clearance is not within specifications, replace the shifter fork as required.
Clearance (a):
9.4 — 10.0 mm (0.370 — 0.394 in)
|
(a) |
Measured value |
|
(A) |
1st driven gear |
|
(B) |
Coupling sleeve |
|
(C) |
2nd driven gear |
|
1st-2nd shifter fork | ||
|
Part No. |
Mark |
Contents |
|
32804AA120 |
1 |
Approaches 1st gear by 0.2 mm (0.008 in). |
|
32804AA130 |
No mark |
Standard |
|
32804AA140 |
3 |
Approaches 2nd gear by 0.2 mm (0.008 in) |
4. Inspect the clearance between the 3rd, 4th drive gear and the coupling sleeve. If any clearance is not within specifications, replace the shifter fork as required.
Clearance (a):
7.4 mm (0.291 in)
Clearance (b):
9.3 mm (0.366 in)
|
(a), (b) |
Measured value |
|
(A) |
3rd drive gear |
|
(B) |
Coupling sleeve |
|
(C) |
4th drive gear |
|
3rd-4th shifter fork | ||
|
Part No. |
Mark |
Contents |
|
32810AA061 |
1 |
Approaches 4th gear by 0.2 mm (0.008 in). |
|
32810AA071 |
No mark |
Standard |
|
32810AA101 |
3 |
Approaches 3rd gear by 0.2 mm (0.008 in) |
5. Inspect the clearance between 5th, 6th drive gear and coupling sleeve. If any clearance is not within specifications, replace the shifter fork as required.
Clearance (a):
8.8 mm (0.346 in)
Clearance (b):
9.4 mm (0.370 in)
|
(a), (b) |
Measured value |
|
(A) |
5th drive gear |
|
(B) |
Coupling sleeve |
|
(C) |
6th drive gear |
|
5th-6th shifter fork | ||
|
Part No. |
Mark |
Contents |
|
32940AA020 |
1 |
Approaches 5th gear by 0.2 mm (0.008 in). |
|
32940AA030 |
No mark |
Standard |
|
32940AA040 |
2 |
Approaches 6th gear by 0.2 mm (0.008 in). |
6. Inspect the rod end clearances (A) and (B). If any clearance is not within specifications, replace the rod or fork as required.
Clearance (A):
1st-2nd — 3rd-4th
0.1 — 0.9 mm (0.004 — 0.035 in)
Clearance (B):
3rd-4th — 5th-6th
0.2 — 1.0 mm (0.008 — 0.039 in)
|
(A), (B) |
Measured value |