Make certain transmission is in the neutral position ! Rolling the gear shifter drum while simultaneously rotating either the drive sprocket gear, or the clutch gear, will allow you to go through the gear ranges, until you locate the neutral position. KEEP AN EYE ON THE SHIFTER FORK SHAFT while doing this !! Check it often ! You will know you have found the neutral position when both the gear shifter cam plunger ball drops into the neutral pocket on the edge of the gear shifter cams body exterior, and the clutch gear remains motionless, while rotating the drive sprocket gear. When rotating the clutch gear in the neutral position, the drive sprocket gear will remain motionless also. Referencing the previous photograph above, we will make certain to keep the backlash out of the gear shifter cam, in the direction of the drive sprocket gear. Note....The back lash procedure will allow us to know the widest point of clearance we have. If the specific clearance tolerance, for correct fitment, is ...say... .052" to .058", the .058" would be our maximum clearance number value, with all back lash taken out. Since .003" to .005" is our final gear shifter cam end play tolerance, and.... we know what shim we will need in the opposite end of the gear shifter cam [ if one should be needed ], in order to obtain these tolerances, we also know, how much the gear shifter cam will travel, in the other direction, upon final assembly. In other words, if we hit the maximum wide tolerance of .058", with the gear shifter cam and the shifter clutches, back lashes taken out, we can subtract our obtained clearance from this value, and then know our minimum clearance obtained. If our gear shifter cam shaft end play clearance will be .003", we subtract this value from our .058" value and we now have a minimum clearance value of .055", on the particular gear shifter clutch we were adjusting. Our minimum and maximum values now fall within tolerance specifications. Although, we managed to obtain clearance values within acceptable levels, It would be best if we can nail our tolerances, dead nuts on, “in the middle of the acceptable tolerance range“. WHY ???? We have other components which will wear as the transmission is in operation. Each shifter fork will wear thinner on both sides, creating more clearance. The gear shifter paths, which are cut into the gear shifter drum, will wear wider, creating more clearance as well. Shifter clutch fork grooves will wear wider. Gear faces will wear. etc... Our goal is to obtain the best clearance values now, so the transmission will provide us with more life. We can miss the mid range values and the transmission will still function very well. We will sacrifice life expectancy though. OK....Now more lecturing. LOL !
We will now proceed to measure our present, low and 2nd &high shifter clutch clearances. Referencing the next two photographs below, we will check our present low and 2nd & high shifter clutch clearances. The first image below shows the use of a small hole gauge, which is fitted between the face of the low gears teeth and the low gear shifter forks face. I like using a small hole gauge for the low gear shifter fork clearance measurement. The tool is a precise expandable and collapsing measuring device, which works perfectly for this particular gear shifter clutch. An outside mic is used to measure the small hole gauge, once feel has been set, after gauging with it. Stacked feeler gauge leaves will work also, but they are difficult to keep stacked while taking measurements. They are also difficult to feel with when stacked. Fractional, letter, and number drill bits [ the shank ends ], work well also. These can be used as go and no go gauges and feel is good with them. Note....mic the drill bits for actual diameter. They are not always what they say they are. Once you have obtained a present clearance value on the low shifter clutch, you now know where this clearance stands, in reference to the tolerance range of factory specifications. As you may recall, when we assembled both shifter fork assemblies, we had assembled, one each, 2253-33B -.007” and 2253-33A - .014” shims, to each of them. Our present, initial, clearance value taken, on the low gear shifter clutch, will now determine, whether we add or subtract from these shims. This same mathematical formula, will be use on the clearance value found, when we take our initial 2nd & high shifter clutch clearance measurement. Moving over to the 2nd & high shifter clutch.... The only real difference between measuring the 2nd & high and low shifter clutches, is where the 2nd & high shifter clutch measurement is taken. The method of taking the measurement is pretty much the same. Measurement is taken between the protruding drive dog faces on the 2nd & high shifter clutch and the protruding drive dog faces on the 2513-41 clutch gear. Rotate clutch gear so protruding drive dogs line up with protruding drive dogs on 2nd & high shifter clutch. Initially I use stacked feeler gauge leaves on my first measurement. Though not as accurate for measurement taking, the stack feeler gauge leaves provide me with a reference point. This reference point allows me to choose selected sized fractional, letter, and number sized drill bits, for a more accurate measurement. I would use a smaller precision small hole gauge here, but my set does not go down that small. I have to improvise instead. You can also use wire gauges or a combination of one drill bit size and one feeler gauge leaf. OK...Back to the 2nd & high shifter clutch clearance measurement....Once you have obtained an accurate measurement, you now know whether you will add or subtract shims, on this shifter fork assembly as well. Once accurate measurements are taken, and it has been determined whether you will remove or add shims, to the two shifter fork assemblies, you get to disassemble the gear shifter cam and the gear shifter fork assemblies once again. LOL !! With accurate measurements, correct mathematics, a bit of luck, the next assembly of these components will be you last assembly of them. After correcting the shims on both shifter clutches, reinstall all components and re take both shifter clutch clearance measurements. If within tolerances, partially remove the gear shifter cam shaft from the gear shifter cam, only enough to allow you to install the gear shifter cam endplay shim, if one would be needed, in front of the gear shifter cams gear face, and aligned with the bore of the gear shifter cam. Install the 2245-36A oil seal onto the gear shifter cam shaft [ fits in groove on gear shifter cam shaft ] [ sprocket side of transmission ] and re insert the gear shifter cam shaft into the gearbox bore. Lock gear shifter cam into place with the 2244-38A screw. The screw threads into the hole on top of the clutch gear side of the transmission case. Tip of screw locates in groove of gear shifter cam shaft......... If not within tolerances yet........Start the whole shifter clutch adjusting procedure all over again...LOL !