Transmission Reassembly

Reassembly

NOTE:
- Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact surfaces.
- 6-speed model is shown, 5-speed model is similar.





1. Install the magnet (A) and differential assembly (B).





2. Install the 28 mm spring washer (A) and 28 mm washer (B) over the ball bearing (C). Note the installation direction of the spring washer (A).
3. Apply vinyl tape the mainshaft splines (D) to protect the seal. Install the mainshaft and countershaft (E) into the shift forks (F), and install them as an assembly.





4. Install the reverse shift fork.





5. Install the reverse idler gear (A) and reverse gear shaft (B) by aligning the mark (C) with reverse gear shaft hole (D).





6. Install the reverse lock cam (5-speed model).





7. Select the proper size 72 mm shim (A) according to the measurements made during the Mainshaft Thrust Clearance Adjustment. Install the oil gutter plate (B), oil guide plate M, and 72 mm shim into the transmission housing (C).





8. Remove the dirt and oil from the transmission housing sealing surface. Apply liquid gasket (P/N 08718-0001) to the sealing surface. Be sure to seal the entire circumference of the bolt holes to prevent oil leakage.

NOTE: If 5 minutes have passed after applying liquid gasket, reapply it and assemble the housings. Allow it to cure at least 20 minutes after assembly before filling the transmission with oil.





9. Install the 14 x 20 mm dowel pins (A).
10. Set the tapered cone ring (B) (5-speed model) as shown. Place the transmission housing over the clutch housing, being careful to line up the shafts.
11. Lower the transmission housing the rest of the way as you expand the 72 mm snap ring (C). Release the snap ring so it seats in the groove of the countershaft bearing.
12. Check that the 72 mm snap ring is securely seated in the groove of the countershaft bearing.
Dimension (1) as installed: 3.3 - 6.0 mm (0.13 - 0.24 inch)
13. Apply liquid gasket (P/N 08718-0001) to the threads of the 32 mm sealing cap (D), and install it on the transmission housing.





14. Install the harness bracket (A) (6-speed model only), the transmission hanger A (B), the transmission hanger B (C), and the 8 mm flange bolts finger-tight.





15. Tighten the 8 mm flange bolts in a crisscross pattern in several steps.





16. Remove the dirt and oil from the shift lever cover sealing surface. Apply liquid gasket (P/N 08718-0001) to the sealing surface.

NOTE: If 5 minute have passed after applying liquid gasket, reapply it and assemble the housings. Allow it to cure at least 20 minutes after assembly before filling the transmission with oil.





17. Install the 8 x 14 mm dowel pins (A), clutch line clip bracket (B), and shift lever assembly (C).
18. Apply liquid gasket (P/N 08718-0001) to the threads of the interlock bolt (D), and install it on the transmission housing.





19. Install the drain plug (A), filler plug (B), and 10 mm flange bolt (C) with new washers.





20. Install the detent bolts (A), springs, and steel balls with new washers.
21. Apply liquid gasket (P/N 08718-0001) to the threads of the back-up light switch (B), and install it on the transmission housing.





22. Install the Vehicle Speed Sensor (VSS) (A) and O-ring (B).