With the air box and swing arm removed, I can remove the transmission. It is secured to the engine block with three bolts and a nut. To get it out of the frame, I remove the clutch throw-out rod mechanism from the back of the transmission and the foot shift mechanism.
Remove Clutch Throw-out Arm
On the 1983 transmission, the throw-out arm is secured with a bolt, nut and washer.
There is a clutch adjuster nut on the throw-out arm. This adjusts clutch engagement.
Then I remove the rubber bellows that is secured with a steel strap. I use a screw driver to get the bellows off the housing. Inside the bellows is a return spring for the throw-out arm.
Remove Foot Shift Adjustment Linkage
The foot mechanism is attached to the transmission shift shaft lever and the left foot peg assembly.
The foot shift adjustment linkage has a wire clip that secures the cup end of the linkage on the ball of the foot shift lever. I remove the wire clip and then press the cup of the shift adjuster linkage off the ball.
I use the screw driver blade to push the end of the wire clip out of the groove in the cup end of the adjustment linkage and then I rotate the wire 180-degrees. Then I pull the wire out toward the rear.
Sometimes I can pull the shift adjuster linkage cup off the ball with my fingers, but it’s a tight fit so sometimes I use a screw driver blade on the edge of the cup to push it off the ball.
I repeat the procedure on the other end of the shift adjustment linkage that attaches to the transmission shift shaft arm.
Remove Left Foot Peg and Foot Shift Lever
The shift lever is attached to the left foot peg. The foot peg has to be removed to remove the shift lever.
The washer is not the correct kind. I will replace it.
The shift lever attaches to the foot peg with a countersunk Allan bolt from the back side of the foot peg. I remove it.
There is a washer between the foot peg and the foot shift lever.
The foot shift lever wobbled on the foot peg. There is an aluminum shim that was added to try and fix this. The bushing is wallowed out. I will replace it.
Remove Transmission and Clutch Throw-out Rod
The top of the transmission is mounted using the left side bolt and right side nut that secure the air box. The left bottom bolt is a blind Allan bolt and the right lower Allan bolt has a nut to secure it. I remove them.
There is minimal clearance on the bottom left bolt for an Allan wrench. I break the bolt free and then back it out with my fingers.
After the bolts are removed the transmission will hang by the output shaft.
I use a magnet to pull out the clutch throw-out bushing and ball bearing from the throw-out arm hole in the back of the transmission.
I pull the transmission back off the clutch spline to expose the clutch plate push rod. I push it to the rear to remove it.
Here is the clutch throw-out rod assembly.
The rear end of the clutch throw out rod has a bushing that connects to the other side of the ball bearing. It has become welded to the throw out rod.
And, there is a garter (retaining spring) from the transmission clutch push rod seal on the clutch push rod.
Someone was not careful when they pushed the rod in from the front of the transmission and caught the garter and pulled it out. If that seal is damaged or the garter removed, the transmission gear lube can migrate down the clutch push rod into the engine bell housing and coat the clutch plates.
The end of the rod is in good shape. I’ll clean it up and try to remove the frozen ball bearing bushing and reuse it.
The bushing shows were on the end the the throw-out arm connects with.
Here is the clutch assembly.
The amount of oil in the bottom of the clutch bell housing and on the top of the engine indicate the rear main seal is likely leaking and this could also include transmission gear lube from the damaged transmission input shaft seal. The oil pump cover o-ring could be leaking as well. No worries, as I planned to replace the seal and o-ring.
Here is the transmission after it’s removed. You can see a lot of grunge around the outside of the input shaft seal in the middle of the transmission. Indication of gear lube leaking past that seal.
The bushing cast into the transmission where the clutch cable fits is not damaged.
Here is what the bike looks like now the transmission has been removed.