300120-01
– 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 the 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:
– Replace the bearings.
– Check the needle bushing 4 for stiffness and wear.
» If the needle bushing does not move freely or is worn:
– Replace the needle bushing.
– Check the shift rail 5 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 6 in contact areas C for wear.
» If the sliding plate is worn:
– Change the sliding plate.
– Check return surface D on the sliding plate for wear.
» If deep notches are present:
– Change the sliding plate.
– Check guide pin E for looseness and wear.
» If the guide pin is loose and/or worn:
– Change the sliding plate.
– Preassemble the shift shaft. ( p. 137)
300122-01
– Check the clearance F between the sliding plate and the shift quadrant.
Shift shaft - play in sliding plate/shift
quadrant
0.40… 0.80 mm (0.0157…
0.0315 in)
» If the measured value does not equal the specified value:
– Change the sliding plate.
16.4.33 Preassembling shift shaft
300154-01
– Fix the short end of the shift shaft in a vise.
Guideline
Use soft jaws.
– Mount sliding plate 1 with the guide pin facing down and attach the guide pin to
the shift quadrant.
– Mount preload spring 2.
– Push on spring guide 3, push return spring 4 over the spring guide with the offset
end facing upward and lift the offset end over abutment bolt 5.
– Mount stop disk 6.
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