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10.FINAL REDUCTION/ TRANSMISSION SYSTEM MXU 250 SERVICE INFORMATION GENERAL INSTRUCTIONS • The transmission system can be serviced with the engine installed in the frame. • When replacing the drive shaft, use a special tool to hold the bearing inner race for this operation. SPECIFICATIONS Specified Oil: GEAR OIL SAE 90# Oil Capacity: At change : 0.3 liter (0.264 lmp qt, 0.318 US qt) At disassembly : 0.4 liter (0.352 lmp qt, 0.424 US qt) TORQUE VALUES Transmission case cover bolt 2.
10.FINAL REDUCTION/ TRANSMISSION SYSTEM MXU 250 TRANSMISSION CASE COVER REMOVAL Drain transmission gear oil into a clean container. (Refer to the “TRANSMISSION OIL REPLACEMENT” section in the chapter 3) Remove the three bolts and then remove the drive sprocket cover (see page 6-3). Remove the two bolts and then remove the washer and drive sprocket (see page 6-3). Remove the bolt and then disconnect the drive shift arm from the shift shaft (see page 6-3). Disconnect the speedometer cable (see page 6-3).
10.FINAL REDUCTION/ MXU 250 TRANSMISSION SYSTEM Bearing Bearing Circlip TRANSMISSION CASE COVER DISASSEMBLY Remove the drive axle circlip. Remove the drive axle from the transmission case cover. Remove the bearing circlip for remove the bearing. Inspect the bearing for allow play in the transmission case cover or the bearing turns roughly. If any defects are found, replace the bearing with a new one. Drive Axle Circlip Drive Axle Inspect the drive axle gear teeth for wear or damage.
10.FINAL REDUCTION/ TRANSMISSION SYSTEM Inspect the needle bearing for allow play in the transmission case cover or the bearing turns roughly. If any defects are found, replace the bearing with a new one. MXU 250 Needle Bearing Needle Bearing ASSEMBLY Install the needle bearing. Install the oil seal and bearing. Install the bearing circlip. Install the drive axle and drive axle cirelip. Bearing TRANSMISSION REMOVAL Remove the transmission cover.
10.FINAL REDUCTION/ MXU 250 TRANSMISSION SYSTEM Remove the shift shaft. Shift Shaft Remove the stopper plug. Plug Remove spring, washer and shift cam stopper.
10.FINAL REDUCTION/ TRANSMISSION SYSTEM Remove the transmission guide bar. MXU 250 Guide Bar Shift Cam Remove shift cam. Remove the shift fork.
10.FINAL REDUCTION/ MXU 250 TRANSMISSION SYSTEM Measure the guide bar runout. Out of specification → Replace. Service Limit: Less than 0.03 mm (0.0012 in) ＊ Do not attempt to straighten a bent guide bar. Inspect the shift fork cam follower and shift fork pawl. Scoring/beads/wear → Replace. Shift Fork Cam Follower Shift Fork Cam Pawl Check the shift cam groove and shift cam gear. Wear or damage → Replace.
.FINAL REDUCTION/ TRANSMISSION SYSTEM MXU 250 Shift Shaft Inspect shift shaft gear. Damage → Replace. Inspect shift shaft. Damage/bends/wear → Replace. Shift Shaft Gear Remove the main axle. Main Axle MAIN AXLE DISASSEMBLY Remove the washers, collar, primary driven gear, bush and clutch dog.
10.FINAL REDUCTION/ MXU 250 TRANSMISSION SYSTEM Collar Washers Primary Driven Gear Clutch Dog Bush Main Axle Reverse Wheel Gear Remove the circlip and then remove the washers, reverse wheel gear and needle bearing.
10.FINAL REDUCTION/ TRANSMISSION SYSTEM MXU 250 Inspect the gear teeth. Blue discoloration/pitting/wear → Replace. Inspect the mated dogs. Rounded edges/cracks/missing portions → Replace. MAIN AXLE ASSEMBLY Reverse the “MAIN AXLE DISASSEMBLY” procedures.
10.FINAL REDUCTION/ MXU 250 TRANSMISSION SYSTEM Remove the counter axle. Counter Axle Inspect the gear teeth. Blue discoloration/pitting/wear → Replace. Bolts Primary Drive Axle Oil Seal PRIMARY DRIVE AXLE REMOVAL Remove the clutch/driven pulley. (Refer to the chapter 9) Remove the oil seal, circlip, bolts and plates. Remove the primary drive axle.
10.FINAL REDUCTION/ TRANSMISSION SYSTEM MXU 250 Bearings Inspect the bearings for allow play in the transmission case cover or the bearing turns roughly. If any defects are found, replace the bearing with a new one. Washer INSTALLATION Reverse the “TRANSMISSION REVOVAL” section procedures. Install the main drive axle. (Reverse the “MAIN DRIVE AXLE” procedures.) Install the counter axle. Install the main axle washer. Install the main axle.
10.FINAL REDUCTION/ MXU 250 TRANSMISSION SYSTEM Install the shift cam. Install the shift fork. Install the guide bar. Install the shift shaft. ＊ Make sure that the lever on the gear change switch correctly engages with the locating slot on the shift shaft. Align the mark on the shift shaft gear with the mark on the shift cam gear. Gear Change Switch Install the shift cam stopper and tighten the plug. Torque: 4.8 kgf-m (48 Nm, 35 lbf-ft) Install the dowel pins and a new gasket onto the right crankcase.
10.FINAL REDUCTION/ TRANSMISSION SYSTEM MXU 250 SPEEDOMETER GEAR REMOVAL Disconnect the speedometer cable (see page 6-3). Remove the speedometer gear plug, washer and speedometer gear shaft. Plug Washer INSPECTION Inspect the speedometer gear teeth. pitting/wear → Replace. Plug Remove the transmission case cover (see page 10-3). Inspect the speedometer driver gear teeth on the main axle. Pitting/wear → Replace.
10.FINAL REDUCTION/ MXU 250 TRANSMISSION SYSTEM Inspect the oil seal for wear or damage. If any defects are found, replace the oil seal with a new one. Oil Seal INSTALLATION Reverse the “REMOVAL” procedures.
