7-14 ENGINE BOTTOM ENDITRANSMISSION

Shift Drum and Fork Installation Notes 'Fit the shift fork guide pins into the corresponding
'Appiy a little transmission oii to the shift fork shift drum grooves.
fingersr and fit the shift forks into the gear grooves. 'Apply a little transmission oil to the shift rodr and
slide it into the shift forks.
Shift Fork Identification
"60, KDX80:
Drive shaft 3rd/4th fingers are shorter than those Shift Fork Bending
gear shift fork of the Other 'Visually inspect the shift forks, and replace any
shift forks
Output shaft 5th fork that is bent. A bent fork could cause difficu[ty
fingers are longer than the in shifting, or allow the transmission to jump out
and 6th gear
drive shaft 3rd/4th gear shift of gear when under power.
shift forks
fork

A. Drive Shaft 3rd/4th Cear Shift Fork

B. Output Shaft 5th and 6th Cear Shift Forks

KX80:
Shift Fork/Gear Groove Wear
Drive shaft 3rd/4th gear
fingers are shorter •Measure the thickness of the shift fork fingers,
than those of the Other and measure the width of the shift fork grooves in
shift fork
shift forks the transmission gears.
the thickness of a shift fork finger is less than
Output shaft 5th gear the service limite the shift fork must
guide pin left
shift fork replaced.

Output shaft 6th gear

guide pin right Shift Fingx Thickness
shift fork
3.9—4.O mm
Limit: 3.8 mm
44. v

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A. Output Shaft 5th Cear Shift Fork B. Output Shaft 6th Cear Shift Fork
C. Drive Shaft 3rd/4th Gear Shift Fork A. Shift Fork Finger