Shift Shaft and Fork Assemblies Assemble

Shift Shaft and Fork Assemblies Assemble





1. If the fork leg inserts must be replaced, you should press them in. Ensure they are centered in the housing.





2. Assemble the 1st and 2nd gear fork, if removed, using a NEW roll pin.





3. If the fork leg inserts must be replaced, you must press them into position.





4. If the 3rd and 4th gear fork was removed, you must assemble and affix the fork with the 3rd and 4th gear fork roll pin.





5. Install the new roll pin over the 1st and 2nd gear stop. Screw the shaft and fork assembly in using the insert marks.





6. Install the new roll pin on the 3rd and 4th gear stop.





7. If the fork leg inserts must be replaced, press them in and ensure they enter into the housing.





8. Install the new roll pin into the 5th and reverse gear fork, using the insert marks as a reference.





9. Install the 3 insert springs.





10. Install the 3 insert spheres.





11. Install the previously assembled unit, shafts, and forks.





12. Install the 5th and reverse gear fork and shaft, placing the spheres on the insert marks.





13. Using a 1/2 socket, tighten the 2 screws on the insert system support plate.





14. Install the roll pins in the order indicated.





15. Using a 1/2 socket, tighten the 3 screws on the locking system support plate.





16. Ensure the surface is free from dust and grease and apply gasket maker GMM P/N 1052943.





17. Install the control cover onto the case, assuring the shift forks are aligned with the corresponding synchronizers.





Caution:
Refer to Fastener Caution Fastener Caution.

18. Using a 1/2 socket, tighten the 10 screws on the control cover to 20-24 Nm (18-22 lb ft).





19. Using a 13 mm socket, tighten the breather support screw.





20. Install the shift tower.





21. Using a 10 mm socket, tighten the 4 screws on the shift tower to 8-14 Nm (6-11 lb ft).