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).

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 ⁵⁄₈–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.

(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.

(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 ¼ 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.

(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).