Transmission Reassembly

Transmission Reassembly

NOTE: Prior to reassembling, clean all the parts in solvent, dry them, and apply manual transmission fluid (MTF) to any contact surfaces.

1. Install the release bearing guide (A), new drain plug washer (B), and drain plug (C).





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





3. Install the 28 mm spring washer (A) and 28 mm washer (B) over the ball bearing (C).

NOTE: Install the spring washer in the direction shown.





4. Apply vinyl tape the mainshaft spline (D) to protect the seal. Install the mainshaft and countershaft (E) into the shift forks (F), and install them as an assembly.
5. Install the reverse shift fork.





6. Install the 20 x 36 x 2 mm thrust washer (A), reverse idler gear (B), and reverse gear shaft (C) by aligning the mark (D) with reverse gear shaft hole (E).





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. Clean any dirt or oil from the transmission housing sealing surface.
9. Apply liquid gasket, P/N 08718-0001, evenly to the transmission housing sealing surface of the clutch housing. Install the component within 5 minutes of applying the liquid gasket.

NOTE:
^ If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes.
^ If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.





10. Install the three 14 x 20 mm dowel pins (A).





11. Place the transmission housing over the clutch housing, being careful to line up the shafts.
12. Lower the transmission housing the rest of the way as you expand the 72 mm snap ring (B). Release the snap ring so it seats in the groove of the countershaft bearing.
13. Make sure the 72 mm snap ring is securely seated in the groove of the countershaft bearing.





14. Apply liquid gasket, P/N 08718-0001 (A) evenly to the threads of the 32 mm searing cap, and a 2 mm (0.079 in.) bead around the mating surface of the transmission housing. Install the component within 5 minutes of applying the liquid gasket.

NOTE:
^ If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes.
^ If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.





15. Install the transmission hangers A and B, harness bracket B (C), mount bracket collars (D), and 8 mm special bolts (left-hand threads) finger-tight.

NOTE: The 8 mm special bolts have left-hand threads.





16. Tighten the 8 mm special bolts (left-hand threads) in a crisscross pattern in several steps.





17. Clean any dirt or oil from the shift arm cover sealing surface.
18. Apply liquid gasket, P/N 08718-0001, evenly to the change lever assembly mating surface of the transmission housing. Install the component within 5 minutes of applying the liquid gasket.

NOTE:
^ If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes.
^ If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.





19. Install the two 8 x 14 mm dowel pins (B), change lever assembly (C), and harness bracket A.





20. Apply liquid gasket, P/N 08718-0001 (A) evenly to the threads of the interlock bolt, and a 2 mm (0.079 in.) bead around the mating surface of the transmission housing. Install the component within 5 minutes of applying the liquid gasket.

NOTE:
^ If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes.
^ If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.





21. Install the interlock bolt (D) on the transmission housing.
22. Install the mount bracket collars (A), new 10 mm washer (B), and 10 mm flange bolt (C). Install the new filler plug washer (D) and filler plug (E) finger-tight.





23. Apply MTF to the new O-ring (F), then install the new O-ring, plain washer (G), and the output shaft (countershaft) speed sensor (H).
24. Apply liquid gasket, P/N 08718-0001 (A) evenly to the threads of the back-up light switch, and a 2 mm (0.079 in.) bead around the mating surface of the transmission housing. Install the component within 5 minutes of applying the liquid gasket.

NOTE:
^ If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes.
^ If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.





25. Install the back-up light switch (A) on the transmission housing.





26. Install the detent bolts, spring, and steel balls (B) with new 12 mm washers (C).
27. Install the new 20 mm washer (D), 20 mm bolt (E), and transmission hanger (F).