ENGINE DISASSEMBLY 

8. Check inside the left case on the mounting bosses of the main shaft, lay shaft, shift drum, and kick starter shaft for shims which may stick to these bosses.  Remove them and install on their respective shafts.
9. Remove the crankshaft shimming washers from either the right end of the crankshaft or the -right main bearing, and tag them for identity.
 
NOTE: The amount of end play in each shaft is adjusted individually at the factory with shims of different thicknesses.  Be sure not to mix them up, or the reassembly job will be much more difficult.
TRANSMISSION COMPONENTS

Removal

1. Turn the right-hand engine case so the transmission shafts are pointing upward at a 45 degree angle (see Figure 18).

2. Remove the center case gasket and throw it away.
3. Remove the slotted plastic breather tube.
4. Turn the kick starter shaft clockwise until you can lift the whole assembly out of the right case.
5. Remove the assembly.  Be sure you don't lose any of the shim washers on either end of the shaft.
6. Remove the selector shaft by pulling it straight out.  There are normally no shim washers on the right end of the selector shaft. 7. Hold the transmission lay shaft and main shaft with your left hand and the shift drum and shift fork shaft with your right hand (see Figure 19).  Remove the assembly from the right engine case.
8. The far right-hand gear on the main shaft, the fifth driven gear, will remain in the case.
9. Check the right case for shims on the mounting bosses.  Be sure not to lose any of the shims or mix them up.
10. Remove the two needle bearings and spacer from inside the fifth driven gear on the right case.
11. Pry up the sprocket nut tab washer on the outside of the right case.
12. Gearbox sprocket spanner number UDIO­999-207 is used for 12 tooth sprockets.  Number UDII-999-207 is used for 11 and 13 tooth sprockets.
13. Install the sprocket spanner and sprocket nut wrench number 999-205 (see Figure 20). The sprocket nut has a left-hand thread, so turn it clockwise to loosen it.
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