Tutorial: Transmission

Notes and steps on removing the transmission.

Note Well:

1. Loosen the bolts on the front sprocket before removing the chain.
2. Don't lose the cylinder stud gasket when removing the cylinder.
3. Watch out for the both thrust washers.
4. Don't lose the pins on the shift drum when you flip it over.

Disassembly:

1. Remove the first thrust washer sitting on the big first gear.  (If it's not there, make sure it's not stuck to the crankcase)
2. Remove first gear.
3. Remove the shift drum along with both shafts.
4. Remove fourth gear.
5. Remove the second thrust washer.

Reassembly

1. Install the first thrust washer.
2. Install fourth gear (wear pattern will tell you right side up).
3. Install the drum with counter shaft in place in the "R" fork and just the third gear in the "L" fork.
4. Use an engine mount bolt to center everything.
5. Now install the main shaft - carefully so that it aligns and sets all the way down into the crankcase.
6. Install first gear (the wear pattern will tell you right side up).
7. Install the second thrust washer.

Disassembly

Reassembly