Reassembly
Transmission ReassemblyNOTE: Prior to reassembling, clean all parts in solvent, dry them, and apply lubricant to all contact surfaces.
1. Press the new dust seal (A) into the transmission housing surface, then install the shift lever (B), shift arm (C), 8 mm spring washer (D), and 8 mm special bolt (E).
2. Select the proper size 82 mm shim (A) according to the measurements made during the Mainshaft Thrust Clearance Adjustment. Install it into the transmission housing (B).
3. Install the steel ball (A), relief valve spring (B), oil pump outer rotor (C), oil pump inner rotor (D), and oil pump plate (E).
4. Install the differential assembly (A) and oil pump shaft (B).
5. Install the 64 mm spring washer (A). Note the installation direction of the 64 mm spring washer.
6. Apply tape to the mainshaft splines (B) to protect the seal. Install the mainshaft and countershaft (C) into the shift forks (D) as an assembly.
7. Press the new dust seal (A) into the clutch housing surface, then install the select lever (B), select arm (C), new 5 mm spring pin (D), and new 3 mm spring pin (E).
8. Set the select return spring (A), pin (B), and interlock (C) as shown.
9. Install the shift piece (A) and shift piece shaft (B).
10. Install the 33 mm spring washer (A), Note the installation direction of the spring washer.
11. Install the 20 mm thrust needle bearing (B), 20 mm thrust washers (C), reverse idler gear shaft assembly (D), and reverse shift fork (E) as an assembly.
12. Slide the reverse idler gear shaft assembly (A) on the rib (B) of clutch housing, then install it into the hole (C) of the clutch housing.
13. Install the reverse shift lever (A), and pin (B).
14. Install the oil guide pipe A, oil guide pipe (B), and magnet (C).
15. Remove any dirt or oil from the transmission housing sealing surface. Apply liquid gasket (P/N 08718-0001) to the sealing surface. Make sure you seal the entire circumference of the bolt holes to prevent oil leakage.
NOTE: If 4 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.
16. Install the 14 x 20 mm dowel pins (A).
17. Lower the transmission housing,then place the shift arm (B) in the groove of the shift piece (C) by turning the change lever (D).
18. Lower the transmission housing the rest of the way as you expand the 75 mm snap ring (E). Release the snap ring so it seats in the groove of the countershaft bearing.
19. Check that the 75 mm snap ring is securely seated in the groove of the countershaft bearing.
Dimension (1) as installed: 9.91 - 11.52 mm (0.390 - 0.454 inch)
20. Install the new 37.7 mm O-ring (F) and transmission case cap (G).
NOTE: Check the operation of the change lever.
21. Install the transmission hanger (A), transmission hanger (B), 8 mm flange bolt (C), and the 10 mm flange bolts finger-tight.
22. Tighten the 10 mm flange bolts in a crisscross pattern in several steps.
10 x 1.25 mm: 44 Nm (4.5 kgf-cm, 33 ft. lbs.)
23. Install the oil check bolt (A), new 6 mm washer (B), drain plug (C), and new 14 mm washer (D).
24. Apply liquid gasket (P/N 08718-0001) to the set screws, then install the set screws (A), 22 mm spring (B), 27.4 mm spring (C), steel balls (D), input shaft (mainshaft) speed sensor (E), output shaft (countershaft) speed sensor (F), and new O-rings (G).
25. Apply liquid gasket (P/N 08718-0001) to the set screws, then install 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).
26. Remove any dirt or oil from the reverse lockout solenoid sealing surface. Apply liquid gasket (P/N 08718-0001) to the sealing surface.
NOTE: If 4 minutes have passed after applying liquid gasket, reapply it, and install the reverse lockout solenoid. Allow it to cure at least 20 minutes after assembly before filling the transmission with oil.
27. Install the transmission harness stay (A) and the reverse lockout solenoid (B).
28. Apply liquid gasket (P/N 08718-0001) to the threads of the back-up light switch (C), and install the switch in the transmission housing.
29. Install the strainer cover (A), new O-ring (B), strainer set spring (C), and oil pump strainer (D).