INSTRUCTIONS. Disassembly. Shifter Cam Assembly. Shifter Forks

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Noreen Jordan
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1 INSTRUCTIONS Disassembly To protect against accidental start-up of vehicle, always disconnect the negative battery cable before working on the motorcycle. Failure to disconnect the battery cable could result in serious injury or death. 1. Remove battery negative cable (black) from battery negative (-) terminal. 2. Remove exhaust system. 3. Remove the magnetic drain plug at the bottom right side of the oil pan and drain the transmission fluid. Remove the fill plug/dipstick. 4. Remove connector from neutral safety switch. 5. Remove the five socket head cap screws from the transmission top cover. Remove the top cover from the transmission case. Do not re-use the top cover gasket. 6. Remove the four bolts and washers from the right and left shifter cam support blocks. Raise the shifter pawl and lift the shifter cam assembly from the dowels on the transmission case. Exploded View Coil Spring Spring Hanger Whittier Blvd. Whittier Ca (562) Fax: (562) Cam Follower Arm s 7. If necessary, disassemble the shifter cam assembly as follows: a. Lift detent arm and slide right support block off end of shifter cam. Remove pivot screw to release detent arm,spring sleeve and spring. Remove retaining ring (Do not re-use). If the needle bearing is damaged, remove the bearing from the support block by pressing it out and replace with a new bearing. b. Moving to opposite side, using a snap ring pliers remove retaining ring from groove at left end of shifter cam. Slide left support block off end of shifter cam. DO NOT re-use retaining ring. If the needle bearing is damaged, remove the bearing from the support block by pressing it out and replace with a new bearing. Always wear proper eye protection when removing retaining rings. Failure to do so may result in eye injury. Roll Pin Support Tower (RH) LSD Roller Shaft Roller Support Tower (LH) Cam LSD Cam Bearing Bearing Fig.1

8. Slide rubber boot off clutch cable adjuster. With a 1/2 inch wrench holding the cable adjuster, loosen jam nut to get a significant amount of free play at hand lever. 9.

2 8. Slide rubber boot off clutch cable adjuster. With a 1/2 inch wrench holding the cable adjuster, loosen jam nut to get a significant amount of free play at hand lever. 9. Remove six socket head screws to remove clutch release cover from the transmission side door. DO not re-use the gasket. 10. Remove retaining ring from inner ramp, then lift inner ramp out of clutch release cover. Turn the inner ramp over so that ball pockets are facing outboard. Remove hook of ramp from button on coupling. Remove the coupling from clutch cable end. 11. Unscrew the cable from the clutch release cover. Remove the clutch cable. 12. Remove the mainshaft fork shaft from the hole on the right side of the transmission case by sliding outward, then remove the 1st gear fork shaft by first removing the threaded plug, then slide the shifter fork back and forth until the shouldered head of the fork shaft protrudes through the hole in the bearing housing. Remove the shifter forks from the mainshaft and countershaft grooves. (See Fig. 5 & 6) Check s for Squareness Fig.2 Clutch Release Cover Assembly Inner Ramp Cleaning & Inspection Fig.3 1. Clean all parts with solvent prior to installing any bearings. Blow dry with low pressure air. 2. Inspect roller bearings make sure that bearings rotate freely without binding. 3. Inspect the shifter cam for cracks or wear. Inspect the ends for grooves or pitting. Always install new roller bearings whenever the shifter cam is replaced. : Always wear safety glasses to shield your eyes from airborne dirt and debris. 4. Inspect the shifter fork shaft and replace if bent or damaged. Fig.4 Coupling Clutch Cable 5. Using a small framer s square, verify that the shifter fork shafts are square. If a fork does not rest flat against the square, it is bent and must be replaced. (See Fig. 3) 6. Inspect the shifter forks for wear. With a micrometer or dial caliper, measure the width of the fork where they contact the gear fork grooves. Replace any fork that measures less than (4.32 mm) 7. Inspect the neutral safety switch. Depress plunger and observe the action. Plunger should pop back without binding. The switch is not repairable and must be replaced if inoperable.

Assembly 1. Find the shifter fork with the centered pin.

Slide the two outer forks into mainshaft gear fork grooves so that pins are positioned on the inside (See Fig. 6) 3.

Place 1st gear shifter fork in groove on the trap door side of the countershaft. 5.

Hand thread the plug and then tighten until it bottoms with a 1/4 hex key. 6. Check the sliding movement of the forks and gears. All parts must move freely without binding.

7 1st Gear Identification Always wear proper eye protection when removing retaining rings. 7. If disassembled, assemble shifter cam assembly as follows: a.

Using a suitable driver, press against outer race until bearing makes firm contact with the counter bore. (See Fig. 9) b.

3 Assembly 1. Find the shifter fork with the centered pin. Holding the fork so that the pin is positioned at the rear of the transmission case, install the fork in the countershaft gear fork groove. (See Fig. 6) 2. Slide the two outer forks into mainshaft gear fork grooves so that pins are positioned on the inside (See Fig. 6) 3. Insert the fork shaft into the hole on the right side of the transmission case. Slide the shaft through the shifter forks and into the hole on the left side of the case. 4. Place 1st gear shifter fork in groove on the trap door side of the countershaft. 5. Insert the short fork shaft with the shoulder in last into the forward hole on the right side of the transmission case. Hand thread the plug and then tighten until it bottoms with a 1/4 hex key. 6. Check the sliding movement of the forks and gears. All parts must move freely without binding. Shifter Shaft Centered Pin Counter Shaft s Fig.6 Main Shaft Offset Outboard 4th & 6th Gear 2nd Gear 3rd & 5th Gear Left Side Right Side Fig.5 Remove Fork Shaft/s (Right Side View) Fig.7 1st Gear Identification Always wear proper eye protection when removing retaining rings. 7. If disassembled, assemble shifter cam assembly as follows: a. Place Left support block under ram of arbor press. Center new roller bearing over bore with the lettered side up. Using a suitable driver, press against outer race until bearing makes firm contact with the counter bore. (See Fig. 9) b. Slide left support block onto end of shifter cam then secure with a new retaining ring. c. Center a new roller bearing over right support block with the lettered side up. Using a suitable driver, press against outer race until bearing makes firm contact with the counterbore. (See Fig. 10) d. Raising the detent arm up, slide right support block onto opposite end of shifter cam. e. To replace the detent spring or detent arm assy., carefully remove the spring by lifting up on the looped end from the detent arm with a flat blade screwdriver and sliding it off the spring hanger. If necessary, drive the hollow roll pin out of the right support block and remove the spring hanger and detent arm to replace the detent arm assy. (See Fig. 11)

6. When installing the Shifter Cam Assy., verify that four locating dowels are in place on deck of transmission case. 7.

While aligning the holes in the support blocks to the transmission case, slide the shifter forks as necessary so that the fork

Start the SHC screws (with flat washers) by hand to fasten the right and left support blocks to the transmission case.

Shifter cam installation is as follow: a.

transmission is in neutral. (See Fig. 6) b.

Pawl adjustment as follows: a. With the transmission in 3rd gear, move the shift lever on the transmission forward and back.

The adjuster screw is eccentric having a total of 1/2 turn of adjustment, so a small amount of rotation of the eccentric screw

When tightening the jam nut, be sure to hold the eccentric screw and then recheck the pawl movement.

4 6. When installing the Shifter Cam Assy., verify that four locating dowels are in place on deck of transmission case. 7. Raise the shifter cam pawl and place the shifter cam assembly over the locating dowels. While aligning the holes in the support blocks to the transmission case, slide the shifter forks as necessary so that the fork pins engage the channels in the shifter cam. 8. Start the SHC screws (with flat washers) by hand to fasten the right and left support blocks to the transmission case. Then tighten the four support block SHC screws to in-lbs (9-12 Nm) in a crosswise pattern. 9. Shifter cam installation is as follow: a. With the forks installed in their correct positions, manually move the shifter forks so there is no gear engagement & the transmission is in neutral. (See Fig. 6) b. With the shifter cam in the neutral position, the detent arm roller will be in the shallowest notch. (See Fig. 10) 10. Pawl adjustment as follows: a. With the transmission in 3rd gear, move the shift lever on the transmission forward and back. The pawl should move an equal distance to the shift pins on the shifter cam. b. The adjuster screw is eccentric having a total of 1/2 turn of adjustment, so a small amount of rotation of the eccentric screw moves the pawl accordingly. c. When tightening the jam nut, be sure to hold the eccentric screw and then recheck the pawl movement. NOTE: The pin on the end of the eccentric adjusting screw must pass through the slot in the pawl arm, it acts as the shift stop. (See Fig. 13) Fig Use a new top cover gasket and align the holes of the gasket, top cover with those in the transmission case. Install the five SHC screws and tighten to in-lbs (9-12 Nm). The long screw is installed in the center hole on the left side of the top cover. 12. Be sure that the case is vented with a down facing rubber hose via the fitting located in the side of the top cover. Groove Locations Main Shaft Fork Groove Counter Shaft Fig.8 Fork Groove Fig.10 Roller Bearing Right Support Block Needle Bearing Left Support Block

Fig.11 Locating Dowels Detent Arm Spring Hanger Spring Spring Sleeve Fig.12 13. Neutral safety switch installation is as follows: a.verify that the transmission is in neutral. b.

Tighten to 120-180 in-lbs (13.6-20.3 Nm.) d.install the connector/s on neutral switch stud/s. 14. Install Clutch cable fitting into clutch release cover. Do not tighten at this time. 15.

Holding inner ramp and coupling together, turn the assembly over. Place the inner ramp (ball socket side down) over balls in outer ramp sockets.

Verify that the two locating dowels are in place on the transmission side door. Place a new gasket on the dowels. 17.

Tighten the clutch cable fitting to 36-60 in-lbs (4-7Nm). 19. Install the transmission drain plug using Teflon tape or pipe compound to seal. (1/8 NPT fitting).

5 Fig.11 Locating Dowels Detent Arm Spring Hanger Spring Spring Sleeve Fig Neutral safety switch installation is as follows: a.verify that the transmission is in neutral. b.lubricate the neutral safety switch O-ring with clean transmission oil. c.using appropriate size box end wrench, install neutral switch with O-ring in the transmission top cover. Tighten to in-lbs ( Nm.) d.install the connector/s on neutral switch stud/s. 14. Install Clutch cable fitting into clutch release cover. Do not tighten at this time. 15. Hold clutch cable coupling with button facing outboard. Place cable end in recess of coupling. With ball sockets facing outboard, place hook of inner ramp on button of coupling. Holding inner ramp and coupling together, turn the assembly over. Place the inner ramp (ball socket side down) over balls in outer ramp sockets. Install the retaining ring so that the opening is above and to the right of the outer ramp tang slot in the clutch release cover. 16. Verify that the two locating dowels are in place on the transmission side door. Place a new gasket on the dowels. 17. Holding the clutch release cover in position against transmission side door, Install six socket head screws, then alternately tighten screws to lbs ( Nm) 18. Tighten the clutch cable fitting to in-lbs (4-7Nm). 19. Install the transmission drain plug using Teflon tape or pipe compound to seal. (1/8 NPT fitting). Caution Do not over tighten filler drain plugs as this may cause leaks. 20. Install the transmission Lubricant drain plug and tighten to ft-lbs (19-28 Nm). 21. Fill the transmission with oz. ( ml) of 85/140 Bel Ray transmission lubricant from dry. Install the transmission filler plug/dipstick in the clutch release cover. Tighten the plug to in-lbs ( Nm). 22. Adjust the clutch cable. Fig

MANUAL TRANS OVERHAUL - BORG-WARNER - T56 6-SPEED MANUAL TRANSMISSIONS Borg-Warner T56 (MM6) 6-Speed

IDENTIFICATION MANUAL TRANS OVERHAUL - BORG-WARNER - T56 6-SPEED 1998 MANUAL TRANSMISSIONS Borg-Warner T56 (MM6) 6-Speed Transmission has 2 identification labels, located on lower left side of case. One