16 ENGINE 150
16.4.48 Checking the shift mechanism (200 Duke)
304513-10
– Check the shift forks 1 (see A) for damage and wear (visual check).
» If there is damage or wear:
– Change the shift fork and gear wheel pair.
– Check shift grooves B of shift drum 2 for wear.
» If the shift groove is worn:
– Change the shift roller.
– Check the seat of the shift drum in bearings 3.
» If the shift roller is not seated correctly:
– Replace the shift drum and/or the bearing.
– Check bearing 3 for stiffness and wear.
» If the bearings do not move freely or are worn:
– Change the bearing.
– Check shift rail 4 on a flat surface for run-out.
» If there is run-out:
– Change the shift rail.
– Check the shift rail for scoring, signs of corrosion and stiffness in the shift forks.
» If there is scoring or corrosion, or if the shift fork is stiff:
– Change the shift rail.
– Check sliding plate 5 in contact areas C for wear.
» If the sliding plate is worn:
– Change the shift shaft.
– Check return surface D on the sliding plate for wear.
» If deep notches are present:
– Change the shift shaft.
– Check guide pin E for looseness and wear.
» If the guide pin is loose and/or worn:
– Change the shift shaft.
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