Usage:
Shift Cap Components
(1) Cotter pin. (2) Clevis pin. (3) Shaft. (4) Seal. (5) Plug. (6) Reducer and breather assembly. (7) Cap. (8) Roll pins. (9) Shift rail. (10) Inhibitor pin. (11) Snap rings. (12) Nut. (13) Lever. (14) Bolt. (15) Forks. (16) Balls. (17) Springs. (18) Pins. (19) Clevis pins. (20) Inside lever.
Disassemble Shift Cap
1. Remove two bolts and lock washers securing parking brake lever (22) to shift cap (21).
2. Remove four bolts and washers securing neutral start switch (23) and shift cap (21) to the four-speed gearbox.
3. Remove the neutral start switch and shift cap. Discard gasket (24). This must be replaced with a new part during assembly.
4. Remove nut (12) and bolt (14) securing lever (13) to shaft (3).
Side View (Cutaway) of Shift Cap
5. Remove two roll pins (8) from the ends of shift rail (9).
6. Remove two plugs (5) from the ends of shift rail (9). Dislodge one plug by striking with a punch. Drive the shift rail against the other plug to knock it out of place.
7. Drive shift rail (9) so that approximately 13 mm (.5 in.) extends outside cap (7).
8. Position both forks (15) in a neutral detent. The inside faces of the forks will be approximately 38 mm (1.5 in.) apart when positioned correctly.
Front View (Cutaway) of Shift Cap
9. Remove one of the snap rings (11) from inhibitor pin (10) inside the shift cap.
10. Insert a punch in the roll pin hole at the end of shift rail (9). Use the punch to rotate the shift rail slightly while removing inhibitor pin (10).
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When removing shift rail (9) in the following step, springs (17) will propel balls (16) through the openings in the bottom of forks (15). Shield these openings to prevent injury from flying parts. |
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11. Remove shift rail (9) from cap (7).
12. Remove two forks (15) from inside the shift cap.
13. Thread reducer and breather assembly (6) out of the top of cap (7).
14. Remove cotter pin (1) and clevis pin (2) from inside cap (7). These parts secure inside lever (20) to shaft (3). Clevis pin (2) should drop through the hole in the top of cap (7).
15. Pull shaft (3) out of inside lever (20) and cap (7). Knock plug (5) out of the cap.
16. Remove inside lever (20) from cap (7).
17. Disassemble inside lever (20), if desired, by driving out roll pins (19) and removing pins (18).
18. Remove seal (4) from cap (7). Discard the seal. This must be replaced with a new part during assembly.
19. Clean all parts thoroughly in a suitable solvent. Inspect parts for damage or excessive wear. Replace parts as necessary.
Assemble Shift Cap
Front View (Cutaway) of Shift Cap
1. Grease the inside lip of a new seal (4) and install into cap (7). The closed side of the seal must face the outside of the cap.
2. Install two pins (18) to inside lever (20), if removed. Secure with roll pins (19).
3. Hold inside lever (20) in place inside cap (7). Install shaft (3) through seal (4) and inside lever (20). Work carefully to avoid damaging the seal.
4. Install clevis pin (2) through the breather hole in the top of cap (7). Rotate shaft (3) as needed, so the clevis pin is fully inserted through inside lever (20).
5. Secure clevis pin (2) with cotter pin (1).
6. Install plug (5) into cap (7) at the end of shaft (3). Seat the plug by tapping with a hammer.
Side View (Cutaway) of Shift Cap
7. Install shift rail (9) half-way into cap (7). Rotate the shift rail so the detents are away from the top of the cap.
8. Install spring (17) and ball (16) into one fork (15).
9. Press ball (16) to hold the spring compressed. Install the fork assembly inside the cap, onto shift rail (9).
10. Install spring (17) and ball (16) into the remaining fork (15).
11. Press ball (16) to hold the spring compressed. Install the second fork assembly onto the shift rail.
NOTE: The two forks (15) must be oriented so that the inside faces of the forks are toward each other.
12. Install shift rail (9) the rest of the way into the cap. Rotate the shift rail and position forks (15) so that balls (16) pop into the neutral detents in the shift rail.
13. Install two roll pins (8) into cap (7) and through the ends of shift rail (9).
14. Install two plugs (5) into cap (7) at the ends of the shift rail. Seat the plugs by tapping with a hammer.
15. Install inhibitor pin (10) into the shift rail, between the shift forks. Secure with snap rings (11).
16. Install lever (13) to shaft (3). Secure with bolt (14) and nut (13).
17. Make sure both forks (15) are held in a neutral detent. The inside faces of the forks will be approximately 38 mm (1.5 in.) apart when positioned correctly.
18. Move lever (13) to all positions and observe the two forks. Pins (18) on the inside lever must engage both forks. Forks must slide smoothly on the shift rail.
19. Install a new gasket (24) onto the four-speed gearbox. Install shift cap (22) and neutral start switch (23), and secure with four bolts and washers.
20. Install two bolts and lock washers securing parking brake lever (22) to shift cap (21).