Service Manual

CLEANING AND INSPECTION
Clean all parts in solvent, except seals and plastic
parts. inspect all parts for general serviceability and
also for the following defects:
Spur Gears Worn, chipped or missing teeth, ex-
cess wear or scoring in the hub bore, or wear and
chipping in the clutch engagement slots.
Bevel Gears Worn, chipped, or missing teeth;
excess wear or scoring in the hub bore. Unusual or
uneven wear pattern on
teeth indicates improper
shimming of input/drive shafts.
Shafts Excessive wear or scoring where contact
is made with gears or bearings. Damaged keyways
and snap ring grooves.
Clutch Collars Wear or scoring in bore; chipped,
cracked or excessively worn (rounded corners) on
clutch "ears".
Bushings/Bearings Wear or scoring; loose, miss-
Shift Forks Wear, cracks, breaks, or bending.
Brake Disc and Pucks Wear, scoring.
Case Halves Cracks, distortion, or worn bearing
,ing or damaged needles.
bores.
SPECIAL NOTE
Refer to Service Bulletin 244 for information
1. Correction of poor clutch action due to
abrupt engagement of transmission drive
belt, which can place high loads on in-
ternal parts.
2. Correction of interference between shift
' stick and frame, preventing proper en-
gagement of 2nd gear.
3. Stronger Hi-lo shift fork.
concerning:
REASSEMBLY
I
NOTE
Grease used during assembly is Shell Darina
"o", unless specified otherwise.
I
INPUT SHAFT
Needle bearings are pressed into case half as
shown in Fig.
12. Pack the needle bearings and the
cavity between them with Exxon Unirex
N-3 grease.
install the square section O-ring at
the bottom of the
input shaft bore; this O-ring
is used to keep the spe-
cial grease in the input shaft bore.
The bevel gear
is a press fit on the input shaft, and
is secured in place with a snap ring. Assemble the
gear on
the shaft, if removed, and install the snap
ring with the sharp edge away from the gear. Install
the input shaft, with washers placed
as shown in
Fig.
12. The snap ring should be installed with the
sharp edge away from the shim washer.
FIG. 12. input Shaft Assembly
HI-LO SHIFT
Apply a light coat of grease to the Hi-Lo shift
cavity in the upper case half. Install the shift fork,
detent pin and spring, shift lever and cover (Fig.
13).
Shift from Hi to Lo several times to check for free
action.
FIG. 13. Hi-lo Shift Assembly
SHIFT FORKS
Apply Loctite to four screws used to secure shift
forks. Coat parts with grease, then install the shift
forks, support plate and lockout plate;
the shift forks
are interchangeable side to side (Fig.
14). install and
tighten the screws evenly, then back
off turn to
free shift forks.
FIG. 14. Assemble Shift Forks
12