Fit the steel balls into the 5th gear holes in the output shaft.
5th Gear [A] Output Shaft [B] Steel Balls [C]
NOTICE
Do not apply grease to the balls to hold them in place. This will cause the positive neutral finder mechanism to malfunction.
After assembling the 5th gear with steel balls in place on the output shaft, check the ball-locking effect that the 5th gear does not come out of the output shaft when moving it up and down by hand.
1. 1st Gear
2. 2nd Gear
3. 3rd Gear
4. 4th Gear
5. 5th Gear
6. 6th (Top) Gear
7. Drive Shaft
8. Output Shaft
9. Circlip (Turn the punch mark to the gear.)
10. Toothed Washer
11. Toothed Washer
12. Toothed Bushing, L = 15 mm (0.60 in.)
13. Toothed Washer
14. Circlip (Turn the punch mark to the washer.)
15. Bushing, 31 mm (1.2 in.)
16. Toothed Bushing, L = 9.4 mm (0.37 in.)
17. Washer
18. Bushing, 25 mm (1.0 in.)
Shift Drum and Fork Removal
Refer to the Transmission Assy Disassembly.
Shift Drum and Fork Installation
Refer to the Transmission Assy Assembly.
KIBS Equipped Models
1. Clutch Cable
2. Vacuum Hose (Equipped Models)
3. Left Switch Housing Lead
4. Main Harness
5. Front Brake Hose
6. Throttle Cables
7. Right Switch Housing Lead
8. Bracket (Hold the brake pipes.)
9. Run the meter lead to outside of the meter bracket.
10. Run the vacuum hoses to inside o ...
Stem, Stem Bearing Installation
Replace the bearing outer races with new ones.
Drive them into the head pipe at the same time.
Special Tools - Head Pipe Outer Race Press Shaft [A]:
57001-1075
Head Pipe Outer Race Driver,
55 [B]: 57001
-1446 or Bearing Driver Set: 57001-1129
Apply grease to the outer races.
...
Terminal Numbers of ECU Connectors
1. Subthrottle Valve Actuator: Y/BK
2. Subthrottle Valve Actuator: BK/O
3. Unused
4. Front Wheel Rotation Sensor Signal: G/Y
5. Unused
6. Starter Lockout Switch: R/G
7. Gear Position Switch: G/R
8. Crankshaft Sensor (–): BK
9. Power Supply to Sensors: BL
10. Unused
11. Intake Air Pre ...