7 - 71
7 Transmission Repair
7E Tuff Torq K210A
Figure E-38. Measure Shift Key Spring Tension
7. Install washer, sprocket, washer and neutral collar
onto shift shaft.
NOTE: The step on the inner diameter of the neutral col-
lar faces away from the chain sprocket, and toward the
gears.
8. Install roller chain over shift shaft chain sprocket.
6. Measure shift key spring tension by pushing all three
keys into grooves and using spring gauge (or postal
scale) to measure force required to hold one spring
down.
Shift Key Spring Force: 2.75–3.0 kg (6–6.5 lbs)
Figure E-39. Assemble Shift Shaft
Washers
Neutral
Collar
9. Install reduction shaft chain sprocket (A) onto roller
chain (already around shift shaft sprocket from step 8
above).
10. Slide reduction shaft (B) through reduction shaft
chain sprocket (A).
11. Install reduction shaft collar (C) and press 35 tooth
spiral cut ring gear (D) and roller bearing (E) onto end
of reduction shaft (B).
12. Install 62 tooth shift gear (F) onto shift shaft (G)
against neutral collar.
13. See figure 4m-20. Alternate installing washer and
shift gears on shift shaft in following order:
49 Tooth Shift Gear (H)
38 Tooth Shift Gear (I)
34 Tooth Shift Gear (J)
30 Tooth Shift Gear (K)
24 Tooth Shift Gear (L)
14. Install toothed washer (M) on shift shaft with flat face
of washer facing 24 tooth shift gear (L).
15. Press roller bearing (N) onto end of shift shaft (G).
F
A
D
E
B
G
I
H
J
K
L
N
Figure E-40. Assemble Shift Shaft Gears
C
M
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