Shift Fork: Service and Repair

DISASSEMBLY





1. Mark gear shifter forks for assembly reference. Position gear shift selector arm plates and gear selector interlock sleeve in the NEUTRAL position. The gear shift selector arm plates should now be centered over the transmission selector lever arm and support.
2. Rotate main shift control shaft counterclockwise. When the gear selector interlock sleeve disengages from the gear shift selector arm plate, pull main shift control shaft rearward. The control selector arm roll pin will now be accessible.





3. Remove control selector arm roll pin using a 5 mm (3/16 inch) diameter pin punch and remove the shifter shaft.





4. Pull main shift control shaft out of case cover using a twisting motion.





5. Remove gear shifter forks, roll pin and gear selector interlock sleeve from case cover.

ASSEMBLY





1. Install a new O-ring seal.





2. If disassembled, assemble the gear shifter forks, gear shift selector arm plates and gear shift fork inserts.





3. NOTE: The narrow side of the C-shaped gear selector interlock sleeve has to be positioned in the case cover slot. The control selector arm roll pin hole has to be toward the rear of the cover.

Install transmission selector lever arm and support and selector interlock plate as an assembly.





4. NOTE: The 1-2 gear shifter fork is the larger gear shifter fork. The gear shifter fork offset is to face the rear of the case cover. The 3-4 gear shift selector arm plate is to be positioned under the 1-2 gear shift selector arm plate.

Position gear shifter forks in case cover. Lubricate main shift control shaft with petroleum jelly. Slide shaft through case cover and shift components until it stops against the front of the case cover.





5. CAUTION: Make sure the roll pin is installed slightly below the transmission selector lever arm and support surface. Failure to countersink the roll pin may result in interference between the pin and the gear selector interlock sleeve during shifts.

Make sure flat on shifter shaft is facing upward and install the transmission selector lever arm and support roll pin using a 5 mm (3/16 inch) pin punch.