Assembly.....................................................................5-8
Solenoid Contacts..............................................................5-8
Disassembly................................................................5-8
Assembly.....................................................................5-9
DRIVE
6.1 SPECIFICATIONS: DRIVE
Specifications.....................................................................6-1
6.2 PRIMARY CHAINCASE COVER
General...............................................................................6-2
Removal.............................................................................6-2
Installation..........................................................................6-2
6.3 DRIVE COMPONENTS
Removal.............................................................................6-3
Installation..........................................................................6-4
6.4 PRIMARY CHAINCASE HOUSING
Removal.............................................................................6-8
Inspection...........................................................................6-8
Mainshaft Bearing and Lip Seal.........................................6-8
Removal......................................................................6-8
Installation...................................................................6-8
Mainshaft Bearing Inner Race............................................6-9
Removal......................................................................6-9
Installation...................................................................6-9
Shifter Shaft Bushing........................................................6-10
Installation........................................................................6-11
6.5 CLUTCH
Removal and Installation..................................................6-13
Clutch Pack Only..............................................................6-13
Partial Disassembly...................................................6-13
Cleaning And Inspection...........................................6-13
Assembly...................................................................6-14
Clutch Pack and Bearing..................................................6-15
Complete Disassembly..............................................6-15
Assembly...................................................................6-16
6.6 TRANSMISSION SPROCKET
Removal...........................................................................6-18
Cleaning and Inspection...................................................6-18
Installation........................................................................6-19
6.7 DRIVE BELT
Removal...........................................................................6-21
Installation........................................................................6-21
TRANSMISSION
7.1 SPECIFICATIONS:TRANSMISSION
Specifications.....................................................................7-1
Service Wear Limits............................................................7-1
7.2 TRANSMISSION
Power Flow.........................................................................7-2
Neutral.........................................................................7-2
1st Gear......................................................................7-2
2nd Gear.....................................................................7-2
3rd Gear......................................................................7-2
4th Gear......................................................................7-2
5th Gear......................................................................7-2
6th Gear......................................................................7-2
7.3 SHIFTER LINKAGE
Adjustment.........................................................................7-4
7.4 CLUTCH RELEASE COVER
Removal and Disassembly.................................................7-5
Cleaning and Inspection.....................................................7-5
Assembly and Installation...................................................7-6
7.5 TRANSMISSION ASSEMBLY
Removal.............................................................................7-7
Disassembly.......................................................................7-8
Shifter Cam/Shifter Forks............................................7-8
Mainshaft.....................................................................7-9
Countershaft..............................................................7-13
Replacing Side Door Bearings..................................7-15
Cleaning and Inspection...................................................7-15
Assembly..........................................................................7-15
Installing Side Door Bearings....................................7-15
Countershaft..............................................................7-16
Mainshaft...................................................................7-16
Shifter Cam/Shifter Forks..........................................7-17
Installation........................................................................7-18
7.6 MAIN DRIVE GEAR AND BEARING
Removal...........................................................................7-19
Cleaning and Inspection...................................................7-20
Needle Bearing Replacement...................................7-20
Installation........................................................................7-22
Installing Main Drive Gear Bearing...........................7-23
Installing Main Drive Gear.........................................7-23
Installing Main Drive Gear Seal.................................7-24
7.7 TRANSMISSION CASE
Removal...........................................................................7-26
Installation........................................................................7-27
Disassembly.....................................................................7-28
Shifter Arm Assembly................................................7-28
Cleaning and Inspection...................................................7-28
Assembly..........................................................................7-29
Countershaft Needle Bearing Replacement..............7-29
Shifter Pawl Lever Assembly.....................................7-29
ELECTRICAL
8.1 SPECIFICATIONS: ELECTRICAL
Specifications.....................................................................8-1
8.2 ELECTRICAL CADDY
Removal.............................................................................8-2
Installation..........................................................................8-2
8.3 ELECTRONIC CONTROL MODULE (ECM)
General...............................................................................8-4
Replacement......................................................................8-4
TABLE OF CONTENTS IX
TABLE OF CONTENTS
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