Service Manual — page 387 of 715

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CRANKSHAFT/TRANSMISSION 9-41
Transmission
Shift Fork Bending Inspection
• Visually inspect the shift forks, and replace any fork that is
  bent. A bent fork could cause difficulty in shifting, or allow
  the transmission to jump out of gear when under power.
   90° [A]

Shift Fork/Gear Groove Wear Inspection
• Measure  the thickness of the shift fork ears [A], and mea-
  sure the width of the gear grooves [B].
  If the thickness of a shift fork ear is less than the service
  limit, the shift fork must be replaced.
  Shift Fork Ear Thickness
    Standard:       5.9 ∼ 6.0 mm (0.232 ∼ 0.236 in.)
    Service Limit:   5.8 mm (0.228 in.)
  If the gear groove is worn over the service limit, the gear
  must be replaced.
  Gear Groove Width
    Standard:     6.05 ∼ 6.15 mm (0.238 ∼ 0.242 in.)
    Service Limit:   6.25 mm (0.246 in.)

Shift Fork Guide Pin/Drum Groove Wear
Inspection
• Measure the diameter of each shift fork guide pin [A], and
  measure the width of each shift drum groove [B].
  If the guide pin on any shift fork is less than the service
  limit, the fork must be replaced.
  Shift Fork Guide Pin Diameter
    Standard:       6.9 ∼ 7.0 mm (0.272 ∼ 0.276 in.)
    Service Limit:   6.8 mm (0.268 in.)
  If any shift drum groove is worn over the service limit, the
  drum must be replaced.
  Shift Drum Groove Width
    Standard:     7.05 ∼ 7.20 mm (0.278 ∼ 0.283 in.)
    Service Limit:   7.3 mm (0.287 in.)

Gear Dog and Gear Dog Hole Damage Inspection
• Visually inspect the gear dogs [A] and gear dog holes [B].
  Replace any damaged gears or gears with excessively
  worn dogs or dog holes.