TRANSMISSION
Paragraph
Description 53
Control linkage 54
Replacement of foot starter crank 55
Replacement of starter crank spring 56
Remove transmission 57
Install transmission 58
53. DESCRIPTION.
=a.= Transmission has three speeds: low, second, and high, and is of
the constant‐mesh, non‐selective type. High gear is direct drive. Since
“dogs” on gear shifter clutches are used to engage transmission gears,
it is of great importance that vehicle clutch is correctly adjusted.
Clutch must be fully disengaged when shifting gears, to prevent
clashing of gears, and possible damage to the shifter clutch “dogs”
and transmission gears. It is also important that gear shifter control
linkage be kept in correct adjustment to ensure full engagement of
shifter clutch driving dogs in all positions, thus preventing possible
damage caused by dogs jumping out of engagement under driving load.
Close fitting and needle roller bearings, within the transmission,
necessitate use of engine oil (seasonal grade) in transmission case for
adequate lubrication.
54. CONTROL LINKAGE (fig. 32).
=a. Transmission Shifted to Adjust Front Drive Chain.= The
transmission is located to receive power from front (engine) drive
chain and transmit power through rear drive chain to rear wheel, and
is movable on its mounting for adjustment of the front (engine) drive
chain. When front (engine) drive chain is adjusted, transmission gear
shifter control linkage is affected. Therefore, after each front drive
chain adjustment, gear shifter control linkage must be checked, and, if
necessary, correctly adjusted to ensure proper gear shifting with full
engagement of the gear shifter clutch driving “dogs” as well as prevent
transmission from jumping out of gear under load.
=b. Checking Gear Shifter Control Linkage.= Before making adjustment
to gear shifter control linkage, make the following checks: See that
all linkage points from transmission gear shifter lever to gear shifter
hand lever are well oiled and free‐working. Check hand lever pivot bolt
nut for tightness. Observe whether there is binding or interference
with shifter rod at any point in the shifting range; this sometimes
results from a bent snifter rod. Check whether or not shifter rod
is correctly adjusted so that when hand lever is moved to any gear
position in tank shifter guide, transmission lever moves to the proper
position to fully engage shifter clutch dogs and shifter cam spring
plunger in cam‐locating notch (inside transmission).
[Illustration: RA PD 310229
_Figure 32—Adjusting Gear Shifter Rod_]
=c. Adjusting Gear Shifter Control Linkage= (fig. 32).
(1) Set hand lever in “N” (neutral) position in shifter guide.
(2) Remove nut and bolt to disconnect shifter rod from hand lever.
(3) With slight backward and forward movement of shifter rod, carefully
“feel” transmission lever into exact position where shifter cam spring
plunger (inside transmission) seats fully in cam‐locating notch.
(4) Next, see that hand lever is in exact “N” (neutral) position in
tank shifter guide.
(5) Readjust length of shifter rod by loosening rod end lock nut, and
turning rod end (onto or off rod as necessary) until its bolt hole
lines up with bolt hole in hand lever.
(6) Replace bolt and tighten nut.
(7) CHECK ADJUSTMENT. It is advisable to shift hand lever into “L”
(low) and “S” (second) gear positions and check shifter rod adjustment
to be sure of having best all‐round adjustment.
(8) When shifter clutches become worn or damaged to the extent of
jumping out of engagement under driving load, even though shifter
control linkage is correctly adjusted, transmission must be removed and
referred to higher authority for service.
55. REPLACEMENT OF FOOT STARTER CRANK.
=a. Remove.=
(1) Remove starter crank clamp bolt nut and remove bolt from crank.
(2) Pull starter crank off squared shaft.
=b. Install.= In installing foot starter crank, notch (for clamp‐bolt
clearance) must be in upward position in squared shaft to put return
spring tension on crank.
(1) Use a ⅝-inch, open‐end wrench and turn square shaft
counterclockwise until bolt slot is upward. Hold shaft in this position
and press starter crank onto shaft until clamping bolt can be inserted.
(2) Insert clamp bolt with bolt head toward rear wheel (crank in upward
position) to provide clearance when starter crank is operated.
(3) Fit lock washer and nut and tighten nut securely.
56. REPLACEMENT OF STARTER CRANK SPRING (fig. 33).
=a.= Starter crank spring fits rather snugly behind rear edge of
countershaft sprocket cover; however, it can be removed and installed
without removing sprocket cover.
=b. Remove.=
(1) Remove foot starter crank (par. 55).
(2) With the blade of a screwdriver or with pliers, pry hooked end of
spring off stud. NOTE: _If spring is broken, this operation will not
be necessary._ Pull on spring end, at same time prying spring free of
sprocket cover so as to pull spring off square shaft.
=c. Install.=
(1) Turn squared shaft so that clamp bolt notch is in bottom position.
Engage square hole in spring on shaft with the hooked spring end to
rear, in line with starter spring stud. Work spring onto shaft, prying
it to rear to clear sprocket cover. Press all the way on squared shaft.
[Illustration: RA PD 315720
_Figure 33—Removing Starter Crank Spring_]
(2) Hook end of spring in place on spring stud.
(3) Install foot starter crank (par. 55).
=57. REMOVE TRANSMISSION= (figs. 34 and 35).
=a.= Transmission and clutch are assembled in one unit and must
be removed and installed together. To make sure trouble is in
transmission, check clutch adjustment (par. 48) and transmission
control linkage (par. 54) before replacing a faulty unit.
[Illustration: RA PD 315721
=A=—TOOL BOX AND BRACKET ASSEMBLY AND MOUNTING BOLT, WASHER AND NUT
=B=—BATTERY
=C=—BATTERY BOX REAR MOUNTING BOLTS, WASHERS, FITTINGS AND NUTS
=D=—BATTERY BOX ASSEMBLY AND COVER
=E=—BATTERY BOX FRONT MOUNTING BOLT, WASHERS AND NUT
=F=—TRANSMISSION AND CLUTCH ASSEMBLY
=G=—FRONT CHAIN ADJUSTING SCREW
=H=—TRANSMISSION MOUNTING STUD NUTS AND WASHERS
=J=—REAR CHAIN OILER PIPE
=K=—REAR CHAIN GUARD FRONT MOUNTING BOLT AND WASHERS
=L=—MUFFLER ASSEMBLY AND ATTACHING BOLT, WASHERS AND NUTS
=M=—REAR BRAKE ROD ASSEMBLY, WASHER AND COTTER PIN
=N=—REAR CHAIN GUARD
=O=—REAR BRAKE CLEVIS PIN, WASHERS AND COTTER PIN
RA PD 315721B
_Figure 34—Disassembly for Transmission Removal from Right Side_]
=b. Remove.=
(1) Drop rear end of skid plate (par. 111).
(2) Remove front chain guard (par. 102).
(3) Remove oil bath air cleaner and mounting bracket (par. 80). Lower
bracket bolt also secures clutch cable tube to frame tube bracket on
left side.
(4) Remove engine sprocket and front drive chain (par. 65).
(5) Remove the two mounting screws and locks in engine case to free
inner front chain guard.
(6) Remove tool box from mounting bracket (par. 106). Remove bracket
from frame.
(7) Remove rear brake rod (par. 96).
(8) Remove rear drive chain (par. 63).
(9) Remove rear drive chain guard (par. 102). Remove rear chain oiler
pipe after disconnecting at oil pump.
(10) Remove battery box (par. 105).
(11) Remove nut, washer, and bolt securing clutch tube assembly bracket
to frame bracket on right side of vehicle. Disengage clutch operating
cable end from end of clutch release lever and remove cable and tube
assembly.
(12) Remove gear shifter rod by disconnecting at hand shifter lever and
at transmission gear shifter lever.
(13) Remove the three transmission mounting stud nuts, then remove lock
washers and large plain washers (located under frame bracket), and lift
transmission sufficiently to permit removal of front chain adjusting
screw.
(14) Loosen upper U‐bolts on ignition coil mounting, then remove the
lower U‐bolt nuts and shift coil on frame tube as far as possible
toward the front.
(15) Remove transmission and clutch assembly from vehicle by lifting
complete unit sufficiently to free mounting studs from frame bracket;
then rotate top of transmission backward about 1/4 turn (fig. 34) and
remove unit from left side of frame (fig. 35).
58. INSTALL TRANSMISSION (figs. 34 and 35).
=a. Install from Left Side.= Working from left side of frame, tilt
top of transmission backward, and as unit passes into position, rotate
top forward, until unit is squarely in position and mounting studs pass
through slots in frame mounting bracket.
(1) Shift ignition coil mounting back into correct position and
tighten U‐bolt nuts.
[Illustration: RA PD 315722
_Figure 35—Disassembly for Transmission Removal from Left Side of
Vehicle_
=A=—LEFT FOOTBOARD, CLUTCH PEDAL AND SIDEBAR ASSEMBLY AND
MOUNTING NUTS AND WASHERS
=B=—ENGINE SPROCKET, NUT, KEY AND FRONT CHAIN
=C=—INNER CHAIN GUARD MOUNTING SCREWS AND LOCKS
=D=—INNER CHAIN GUARD
=E=—TRANSMISSION AND CLUTCH ASSEMBLY
=F=—OUTER CHAIN GUARD
=G=—OUTER CHAIN GUARD REAR MOUNTING BOLT, WASHER, SPRING, NUT
AND COTTER PIN
=H=—AIR CLEANER AND BRACKET ASSEMBLY
=J=—AIR CLEANER BRACKET UPPER MOUNTING BOLT NUTS AND WASHERS
=K=—SPARK COIL LOWER MOUNTING U‐BOLT NUTS AND WASHERS
=L=—CLUTCH CABLE AND HOUSING ASSEMBLY AND MOUNTING BOLTS, WASHERS
AND NUTS
=M=—GEAR SHIFTER ROD ASSEMBLY WITH ATTACHING BOLT, WASHERS, PIN
AND NUT
RA PD 315722B
_Legend for Figure 35—Disassembly for Transmission Removal from Left
Side of Vehicle_]
(2) Install front chain adjusting screw. Lift transmission to engage
screw in frame notch.
(3) Install large plain washers, lock washers, and nuts on the three
transmission mounting studs. Do not tighten.
(4) Install gear shifter rod by connecting to hand shifter lever and
transmission gear shifter lever.
(5) Install clutch operating cable and tube assembly. Connect cable
end to clutch release lever. Position tube assembly bracket to frame
bracket and install bolt, washer, and nut to hold in place.
(6) Install battery box (par. 105).
(7) Install rear drive chain guard (par. 102).
(8) Install rear drive chain (par. 63).
(9) Install rear brake rod (par. 96).
(10) Install tool box bracket and tool box (par. 106).
(11) Secure inner front chain guard to engine base by installing screw
locks and screws. After screws are tightened, drift edge of each lock
into screw slot for security.
(12) Install engine sprocket and front drive chain (par. 65).
(13) If necessary, adjust front drive chain (par. 59).
(14) Securely tighten transmission mounting stud nuts.
(15) Install outer front chain guard cover (par. 102). Connect rear
chain oiler pipe to oil pump.
(16) Install air cleaner and mounting bracket, air hose, and
connections (par. 79).
(17) Lift skid plate into position and install two mounting bolts, lock
washers, and nuts.
(18) Check gear shifter control, and, if necessary, adjust linkage
(par. 54).
(19) Check rear drive chain adjustment and adjust if necessary (par.
60).
(20) Check rear brake adjustment. If necessary, adjust rear brake
linkage (par. 96).
(21) Check clutch controls and adjust if necessary (par. 48).
(22) Before operating vehicle, see that transmission oil level is up to
filler opening (vehicle standing upright).