Shift Cover

Disassembly

1. Mark shift forks for assembly reference. Position selector arm plates and selector arm in the NEUTRAL position. The gearshift selector arm plates should now be centered over the control selector arm.
   
   
   
   

2. Rotate shifter shaft counterclockwise. When the selector arm disengages from the selector arm plate, pull shifter shaft rearward. The selector arm roll pin will now be accessible.

   Remove selector arm roll pin using a 5mm (3/16 inch) diameter pin punch and remove the shifter shaft.
   
   
   
   

3. Pull shifter shaft out of cover using a twisting motion.
   
   
   
   

4. Remove shift forks, roll pin and shift interlock from shift cover.
   
   
   
   

Assembly

1. Install a new O-ring seal.
   
   
   
   

2. If disassembled, assemble the shift forks, selector arm plates and nylon inserts.
   
   
   
   

   NOTE: The narrow side of the C-shaped selector interlock plate has to be positioned in the shift cover slot. The control selector arm roll pin hole has to be toward the rear of the cover.

3. Install control selector arm and selector interlock plate as an assembly.
   
   
   
   

4. Position shift forks in cover. Lubricate shifter shaft with petroleum jelly. Slide shaft through shift cover and shift components until it stops against the front of the cover.

   NOTE: The 1-2 shift fork is the larger fork. The shift fork offset is to face the rear of the cover. The 3-4 gear shift selector arm plate is to be positioned under the 1-2 gearshift selector arm plate.

   
   
   
   
   

    CAUTION: Ensure the roll pin is installed slightly below the selector arm surface. Failure to countersink the roll pin may result in interference between the pin and the interlock plate during shifts.

5. Ensure flat on shifter shaft is facing upward and install the control selector arm roll pin using a 5mm (3/16 inch) pin punch.