Shift Shaft And Forks
Inspect the shift fork interlock arms and synchro sleeve contact surfaces (see Fig 1). Replace any fork exhibiting wear or damage in these areas. Do not attempt to salvage shift forks.
Check condition of the shift shaft detent plunger and spring. The plunger should be smooth and free of nicks, or scores. The plunger spring should be straight and not collapsed, or distorted. Minor scratches, or nicks on the plunger can be smoothed with 320/400 grit emery soaked in oil. Replace the plunger and spring if in doubt about condition. Check condition of detent plunger bushings. Replace if damaged.
Inspect the shift shaft, shift shaft bushing and bearing, the shaft lever, and the lever bushing that fits over the lever. Replace the shaft if bent, cracked, or severely scored. Minor burrs, nicks, or scratches can be smoothed off with 320/400 grit emery cloth followed by polishing with crocus cloth. Replace the shift shaft bushing or bearing if damaged.
Replace the shaft lever and bushing if either part is deformed, or worn. Do not attempt to salvage these parts as shift fork binding will occur. Replace the roll pin that secures the lever to the shaft.