Shift Forks, Servicing

Special tools and workshop equipment required

Shift Segment Identification

Fig 1: Identification Of Selector Segments

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Dimension -a-

1 - 1st and 2nd gear shift segments = 11.4 mm

2 - 3rd gear and 4th gear selector segments = 7.7 mm

3 - 5th gear shift segments = 12.1 mm

Removing the Lock Washer

Fig 2: Identifying Removal Of Lock Washer

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-- Secure shift fork in vise with protective jaws -B-.

-- Pry off the lock washer -A- in the direction of -arrow-.

Installing the Lock Washer

Fig 3: Identifying Socket Driver & Jaw Protectors

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-- Press the lock washer in the groove in the shift segment using a socket wrench

NOTE:

The shift segment must still rotate easily after the lock washer is installed.

A - 10 mm socket wrench

B - Protective Jaws

Removing the Angular Contact Ball Bearing

Fig 4: Identifying Angular Contact Ball Bearing

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NOTE:

Be careful not to bend the shift forks when removing and installing the angular contact ball bearing.

Installing the Angular Contact Ball Bearing Inner Race A into the Outer Race

Fig 5: Identifying Angular Contact Ball Bearing Inner Race -A- Pressed Into Outer Race

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The bearing inner race must engage with outer race.

Installing the Angular Contact Ball Bearing into the Shift Fork

Fig 6: Ball Bearing Recess

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The recess in the :3290/1 point to the ball bearing.

Shift fork with the Shift Segments Installed

Fig 7: Allocation Shift Fork (Dimension)

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	Dimension -a- (mm)
1st/2nd gear shift fork	87.2 to 87.4
3rd/4th gear shift fork	93.6 to 93.8

Shift segment allocation. Refer to Fig 1