Gear Change Shaft - Installation

Warning - General - Stabilise Motorcycle

warning
Make sure the motorcycle is stabilised and adequately supported.A correctly supported motorcycle will help prevent it from falling.An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle.
  1. Assemble the detent arm as noted during removal with a new fixing and place up to the crankcase.
    2. Detent Arm plus Exploded (cdnj_1)

    1. Spring

    2. Washer

    3. Detent arm

    4. Flanged sleeve

    5. Fixing

  2. Hold the detent arm assembly in position and insert a new fixing. Start the thread and push the detent arm, using finger pressure only, to locate on the selector drum detent wheel.
  3. Make sure the detent arm remains correctly located on the detent wheel and the spring is correctly seated in the recess in the crankcase. Make sure the shoulder of the flanged sleeve is located in the bore of the detent arm and tighten the fixing to 12 Nm.
    4. Detent Arm (cdnj)

    1. Detent arm

    2. Fixing

    3. Spring

    4. Detent wheel

  4. Rotate the selector drum to the neutral position. Make sure that the detent arm locates in the raised profile in the detent wheel (neutral position).
    5. Neutral Position (cdnj_2)

    1. Detent arm

    2. Neutral position

  5. Using clean engine oil, lubricate the lip of the seal on the gear change shaft.
    6. Shaft Seal/Bearing (cdnj_4)

    1. Gear change shaft seal

    2. Gear change shaft bearing

  6. Lubricate both sides of the forks and slider plates of the selector mechanism on the gear change shaft with new engine oil which meets specification API SH (or higher) and JASO MA.
    7. caution
    Take care to avoid damaging the lip of the seal when inserting the gear change shaft into the crankcase. A damaged seal will lead to oil loss and could result in engine damage.
  7. Insert the gear change shaft into the crankcase. Gently push the gear pedal end of the shaft through the bearing and lip seal at the clutch side of the crankcase, and the sealed bearing, located at the gear pedal side of the crankcase.
    8. Gear Shaft Install (cdnm_1)

    1. Gear change shaft

    2. Abutment bolt

    3. Spring

  8. Make sure the gear change shaft fingers locate in the detent wheel/arm and the spring fits either side of the abutment bolt.
  9. Fit the washer and E-clip to the gear pedal end of the gear change shaft.
    10. Remove E clip and washer kakh_2

    1. Gear change shaft

    2. E-clip

    3. Washer

  10. Refit the baffle plate with two new fixings and tighten to 9 Nm.

Perform the following operations

Perform the following operations:

Clutch - Install L Series