ENGINE REPAIR

23. Install the left case with the gasket between cases.  Tighten the screws.

24. Turn the shaft clockwise until it stops.  Pull the shaft back and forth and measure the end play.  It should be .060" to .080". The amount is not critical, but correct it by adding or subtracting the large diameter shims on the left end of the shaft.

25. Now you know how many shims each shaft needs.  The next step is to determine which end of the shaft they should go on.

26. Install the shift forks on their shaft (see Figure 38).  Install two new snap rings on the shaft with the sharp edges facing inward.
27. Install the two needle bearings in the main shaft fifth driven gear with the 10 mm spacer between them.

28. Make a spacer of the same thickness as the end play of the main shaft you wrote down earlier, out of extra shims from the left end of the lay shaft (see Figure 39) and install it on the right end of the main shaft.

29. Install the transmission assembly as a unit in the right engine case, which should be upright (see Figure 40).  Push all the components to the right side and be sure everything turns freely.

30. Rotate the main shaft while turning the shift drum to change gears, to allow the engaging dogs to move into alignment and mesh with the other gear.


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