Remove the bearing if necessary

Measuring the selector fork end thickness

2*54 Engine, clutch and transmission

30.16a Assemble the selector forks on the gear pinions...

13Inspect the selector drum grooves and selector fork guide pins for signs of wear or damage. If either component shows signs of wear or damage the selector fork(s) and drum must be renewed.

14 Check the selector drum bearing referring to Tools and Workshop Tips (Section 5) in the Reference Section.

Installation

15If removed, press the selector drum bearing onto the drum. Install the pin inthe end of the gear selector drum and install the cam, locating the pin in the cut-out in the back of the cam. Clean the threads of the centre bolt, then apply asuitable non-permanent thread-locking compound. Install the bolt and tighten it to the specified torque setting (see Step 7).

16Slide the selector forks off their shaft and locate the forks in the grooves in the gear pinions (see Steps 3 and 4) (see illustration).Push the forks forward and slide the selector drum into position in the crankcase (see illustration).Make sure the drum end locates into its bore in the casing, and position it so that the neutral contact is against the neutral switch (see Step 2).

17 Apply a suitable non-permanent thread-locking compound to the selector drum bearing retainer plate bolt, then fit the plate and tighten the bolt securely.

18 Lubricate the selector fork shaft with clean engine oil and slide it through the crankcase and each fork in turn, and into its bore, locating the guide pin on the end of each fork into its groove in the drum as you do (see illustration 30.5b).

19Apply a suitable non-permanent thread-locking compound to the selector fork shaft retainer plate bolt, then fit the plate and tighten the bolt securely.

20 Lubricate the selector forks and fork grooves with a 50/50 mixture of molybdenum disulphide grease and clean engine oil. Lubricate the gears, shafts and bushings with clean engine oil.

21 Ensure the gears are in the neutral position and check the shafts are free to rotate easily and independently (ie. the input shaft can turn whilst the output shaft is held stationary).

B ... then slide the selector drum into place

22Install the gearchange mechanism (see Section 19) and check gearchange operation while turning the input shaft.

23 Refit the oil sump (see Section 18) and the clutch (see Section 15)

31 Crankcase halves and cylinder bores - inspection and servicing

Crankcase halves

1 After the crankcase halves have been separated, remove the crankshaft, connecting rods and pistons, transmission shafts, selector drum and forks, and, if required, the oil pressure switch, neutral switch and cooling system union, referring to the relevant Sections of this Chapter, to Chapter 9 for the oil pressure switch and neutral switch, and to Chapter 3 for the coolant union.

2 The crankcases should be cleaned thoroughly with solvent and dried with compressed air. All oil passages should be blown out with compressed air.

3 Inspect the bearing seats for signs of damage, especially if an engine or transmission bearing has overheated or seized (see Section 21). If bearing shells or a ball bearing cage are not a precise fit in their seats, ask your Honda dealer for asuitable bearing locking compound which will overcome small amounts of wear. Otherwise the crankcase halves will have to be renewed as a set.

4 All traces of old gasket sealant should be removed from the mating surfaces. Minor damage to the surfaces can be cleaned up with a fine sharpening stone or grindstone. Caution: Be very careful not to nick or gouge the crankcase mating surfaces or oil leaks will result. Check both crankcase halves very carefully for cracks and other damage.

Date: 2016-01-14; view: 599