Remove the Primary Chaincase
Follow the Service Manual PRIMARY CHAINCASE,
REMOVAL instructions to remove the cover, the primary
chain, clutch, engine compensating sprocket, chain
tensioner assembly, alternator and starter drive mechanism,
and the primary chaincase.
Remove the 5-Speed Transmission
1. Remove the locknut, lockwasher and flat washer to
separate the the shift rod from the 5-speed transmis-
sion shifter arm.
2. Remove oil hose cover and oil hoses at the crankcase.
a. Remove screws and cover.
b. Use side cutters to remove clamps on crankcase end
of oil supply, return and crankcase breather hoses.
3. See Figure 1. Locate vehicle speed sensor and remove
screw and the sensor from the existing transmission
case.
4. See Figure 2. Remove connectors from neutral switch.
5. See Figure 3. Remove the fasteners from the transmis-
sion exhaust bracket.
6. Remove the 4 bolts and washers connecting the trans-
mission to the engine.
NOTE
After removing the bolts, the transmission is unattached to
the frame or the engine and is resting on the support jack.
7. See Figure 4. From the right side,
slide the transmission
toward the rear of the motorcycle (to clear the ring dow-
els) and lift the transmission out of the frame.
Install 6-Speed Transmission
1.
Slide the 6-speed transmission with oil pan from the right
side of the frame into position.
a. Center the the transmission rear mounts between the
rear swingarm mounts.
b. See Figure 4. Move transmission forward to engage the
2 ring dowels in the lower flange of crankcase.
2. Align the bolt holes on the transmission to the engine by
threading in and finger tightening the 4 bolts and washers.
NOTE
Use OPEN End Crowfoot (Snap-On FC018) on the upper
left and upper right transmission housing to crankcase bolts.
3. See Figure 5. Tighten the transmission bolts in a cross
pattern torque sequence:
a. 1
st
pass tighten to 15 ft-lbs (20.3 Nm).
b. 2
nd
pass tighten to 30-35 ft-lbs (40.7-47.5 Nm).
4. Assemble the pivot shaft assembly (pivot shaft, locknut,
cup washer, rubber mount and outer spacer) and coat
the pivot shaft with Loctite
®
Anti-Seize.
2 of 6
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Figure 3. Exhaust Bracket on 5-Speed Side Door
(side cover removed)
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Figure 1. Vehicle Speed Sensor
(behind engine oil fill plug/dipstick)
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Figure 2. Neutral Indicator Switch Connector
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