Disassembly

Transmission Disassembly





Exploded View - Clutch Housing





Exploded View - Transmission Housing

NOTE: Place the clutch housing on two pieces of wood thick enough to keep the mainshaft from hitting the workbench.





1. Remove the strainer cover (A), O-ring (B), strainer set spring (C), and oil pump strainer (D).





2. Remove the transmission harness stay (A), reverse lockout solenoid (B) and back-up light switch (C).





3. Remove the set screws (A), 22.0 mm spring (B), 26.1 mm spring (C), 27.4 mm springs (D), steel balls (E), oil filler plug (F), washer (G), and clutch pipe bracket (H).





4. Remove the set screws (A), 22.0 mm spring (B), 27.4 mm spring (C), steel balls (D), input shaft (mainshaft) speed sensor (E), output shaft (countershaft) speed sensor (F), and O-rings (G).





5. Remove the oil check bolt (A), 6 mm washer (B), drain plug (C), and 14 mm washer (D).





6. Remove the transmission hanger (A), transmission hanger (B), and 8 mm flange bolt (C). Remove the 10 mm flange bolts in a crisscross pattern in several steps.





7. Remove the transmission case cap (A) and 37.7 mm O-ring (B).
8. Expand the 75 mm snap ring (C) on the countershaft ball bearing, and remove it from the groove with snap ring pliers.
9. Remove the transmission housing (D) and 14 x 20 mm dowel pins (E).





10. Remove the oil guide pipe A, oil guide pipe (B), and magnet (C).





11. Remove the pin (A) and reverse shift lever (B).





12. Remove the 20 mm thrust washers (A), 20 mm thrust needle bearings (B), reverse idler gear shaft assembly (C), 33 mm spring washer (D), an reverse shift fork (E) as an assembly.





13. Remove the pin (A), select return spring (B), shift piece shaft (C), shift piece (D) and interlock (E).





14. Remove the 5 mm spring pin, 3 mm spring pin (A), select arm (B), 14 x 20 x 5 mm dust seal (C), and select lever (D).





15. Apply tape to the mainshaft splines to protect the seal, then remove the mainshaft assembly (A) and countershaft assembly (B) with the shift forks (C) from the clutch housing (B).
16. Remove the 64 mm spring washer (E).





17. Remove the oil pump shaft (A) and differential assembly (B).





18. Remove the oil pump plate (A), oil pump inner rotor (B), oil pump outer rotor (C), relief valve spring (D), and steel ball (E).





19. Remove the 82 mm shim (A) from the transmission housing (B).





20. Remove the 8 mm special bolt (A), 8 mm spring washer (B), shift arm (C), change lever (D), and 16 x 23 x 5 mm dust seal (E).