Shafts and Clutches

Mainshaft:

Mainshaft Disassembly, Inspection, and Reassembly
1. Lubricate all parts with ATF during reassembly.
2. Check the clearance of the 3rd/4th clutch assembly.
3. Inspect the thrust needle bearing and the needle bearing for galling and rough movement.
4. Inspect the splines for excessive wear and damage.
5. Check shaft bearing surfaces for scoring, scratches, and excessive wear.
6. Before installing the O-rings, wrap the shaft splines with tape to prevent damage to the O-rings.
7. Install the conical spring washer and 41 x 73 mm thrust shim in the direction shown.
8. Inspect condition of the sealing rings. If the sealing rings are worn, distorted, or damaged, replace them.

3rd/4th Clutch Clearance Inspection
1. Remove the O-rings from the mainshaft.





2. Assemble the 41 x 73 mm thrust shim (A), 3rd/4th clutch assembly (B), and 4th gear collar (CJ on the mainshaft (D).





3. Hold the 4th gear collar (C) against the clutch assembly (B), then measure the clearance between the clutch guide (E) and the 4th gear collar with a feeler gauge (F) in at least three places. Use the average as the actual clearance.
STANDARD: 0.03 - 0.11 mm (0.001 - 0.004 inch)





4. If the clearance is out of standard, remove the thrust shim and measure its thickness.
5. Select and install a new shim, then recheck.





THRUST SHIM, 41 x 73 mm

6. After replacing the thrust shim, make sure the clearance is within standard.

Mainshaft Sealing Rings Replacement
The sealing rings are synthetic resin with chamfered ends. Check condition of the sealing rings, and replace them only if they are worn, distorted, or damaged.





1. For a better fit, squeeze the sealing rings (A) together slightly before installing them.





2. Apply ATF to the new sealing rings then install them on the mainshaft.
3. After installing the sealing rings, verify the following:
- The rings are fully seated in the groove. The rings are not twisted.
- The chamfered ends of the rings are properly joined.

Countershaft Disassembly, Inspection, and Reassembly





1. Remove the locknut, and take off components down to the reverse selector hub.
2. Remove the reverse selector hub, 3rd gear, and 1st gear.
3. Check the bearing in the bearing hub for wear and rough movement. If the bearing is worn or damaged, replace it.
4. Inspect the thrust needle bearing and the needle bearing for galling and rough movement.
5. Check the splines for excessive wear and damage.
6. Check the shaft bearing surfaces for scoring, scratches, and excessive wear.
7. Lubricate all parts with ATF, and reassemble the shafts and gears.
8. Install the conical spring washer, reverse selector, reverse selector hub, and distance collar in the direction shown.

Countershaft Reverse Selector Hub, 3rd Gear, and 1st Gear Replacement

Special Tools Required
Driver 40 mm I.D. 07746-0030100

Removal





1. Remove the reverse selector hub (A) and the 4th gear (B) with a universal two-jaw (or three-jaw) puller (C). Place a shaft protector (D) between the puller and countershaft (E) to prevent damaging the countershaft.

NOTE: Some of the reverse selector hubs are not press-fitted, and can be removed without using a puller.

2. Remove the needle bearing, snap ring, distance collar, and 31 mm cotters from the countershaft.





3. Remove the 1st gear (A) and 3rd gear (B) together from the countershaft (C) with a puller (D). Place a shaft protector (E) between the puller and countershaft to prevent damaging the countershaft.

Installation
1. Apply ATF to the parts.
2. Install the 1st gear on the countershaft by hand.





3. Align the shaft splines with those on 3rd gear, then press the countershaft (A) into the 3rd gear with press.
- Place an attachment (B) between the press and countershaft to prevent damaging the countershaft.
- Stop pressing the countershaft when the 3rd gear contacts the 1st gear (C).
4. Install the 31 mm Dotters, distance collar, snap ring, needle bearing, and 4th gear (A) on the countershaft.





5. Slide the reverse selector hub (B) over the countershaft (C), and then press it into place with the special tool and a press.

NOTE: Some of the reverse selector hubs are not press-fitted and can be installed without using the special tool and a press.

Countershaft Bearing Hub/Bearing Replacement

Special Tools Required
- Driver 07749-0010000
- Attachment, 42 x 47 mm 07746-0010300 Attachment, 62 x 68 mm 07746-0010500

1. Check the bearing for wear, damage, and rough movement. If the bearing is worn or damaged, replace it.





2. Remove the bearing (A) from the bearing hub with the special tools, a bearing separator (B), and a press.





3. Install the new bearing on the bearing hub with the special tools and a press.

Secondary Shaft Disassembly, Inspection, and Reassembly





1. Remove the locknut, and disassemble the shaft and gears.
2. Inspect the thrust needle bearing and the needle bearing for galling and rough movement.
3. Check clearance of the secondary shaft assembly.
4. Check the splines for excessive wear and damage.
5. Check the shaft bearing surfaces for scoring, scratches, and excessive wear.
6. Check the idler gear bearing for wear and rough movement. If the bearing is worn or damaged, replace it.
7. Before installing the O-rings, wrap the shaft splines with tape to prevent damage to the O-rings.
8. Lubricate all parts with ATF during reassembly.
9. Install the conical spring washer and 38 x 56.5 mm splined washer in the direction shown.

Secondary Shaft Clearance Inspection
1. Remove the Wrings from the shaft.





2. Assemble the thrust needle bearing (A), needle bearing (B), 1st gear (C), thrust needle bearing (D), 38 x 56.5 mm splined washer (E), 32 mm cotters (F), cotter retainer (G), and snap ring (H) on the secondary shaft (I).








3. Measure the clearance between the 38 x 56.5 mm splined washer (E) and cotters (F) with a feeler gauge (J) in at least three places. Use the average as the actual clearance.
STANDARD: 0.07 - 0.15 mm (0.003 - 0.006 inch)
4. If the clearance is out of standard, remove the splined washer, and measure its thickness.
5. Select and install a new splined washer, then recheck.





SPLINED WASHER, 38 x 56.5 mm

6. Remove the 27 x 47 x 5 mm thrust washer from the mainshaft.





7. Assemble the 1st/2nd clutch assembly (A), 37 x 55 mm thrust shim (B), thrust needle bearing (C), needle bearing (D), 2nd gear (E), thrust needle bearing (F), and 27 x 47 x 5 mm thrust washer (removed from mainshaft) (G) on the secondary shaft (H).





8. Set the dial indicator (I) on 2nd near (E).





9. Hold the 27 x 47 x 5 mm thrust washer (G) against the clutch assembly (A), and measure the 2nd gear axial clearance in at least three places while moving the 2nd gear (E). Use the average as the actual clearance.
STANDARD: 0.04 - 0.12 mm (0.002 - 0.005 inch)
10. If the clearance is out of standard, remove the 37 x 55 mm thrust shim and measure its thickness.
11. Select and install a new thrust shim, then recheck.





THRUST SHIM, 37 x 55 mm

12. Disassemble the shaft and gears.
13. Reinstall the 27 x 47 x 5 mm thrust washer on the mainshaft.

Secondary Shaft Idler Gear Bearing Replacement

Special Tools Required
- Driver 07749-0010000
- Attachment, 62 x 68 mm 07746-0010500

1. Check the bearing for wear, damage, and rough movement. If the bearing is worn or damaged, go to step 2.
2. Place the secondary shaft idler gear in a vise with soft jaws.





3. Remove the bearing (A) from the secondary shaft idler gear (B) with a commercially available 3-jaw slide hammer (C).





4. Install the bearing on the secondary shaft idler gear with the special tool and a press.

Clutch Disassembly

Special Tools Required
- Clutch spring compressor attachment 07LAE-PX40100
- Clutch spring compressor attachment 07HAE-PL50101
- Clutch spring compressor bolt assembly 07GAE-PG40200 or 07GAE-PG4020A





1. Remove the snap ring (A), then remove the clutch end plate, the clutch discs, and the plates with a screwdriver (B).





2. Remove the disc spring (A) from the 1st, 3rd and 4th clutches.

NOTE: The 2nd clutch does not have a disc spring.





3. Install the special tools on the 3rd/4th clutch assembly.





4. Be sure the special tool (A) is adjusted to have full contact with the spring retainer (B) on the 3rd and 4th clutches.





5. Set the special tool (A) on the spring retainer (B) of the 1st and 2nd clutches in such a way that the special tool works on the clutch return spring (C).





6. If either end of the special tool is set over an area of the spring retainer, which is unsupported by the return spring, the retainer may be damaged.





7. Compress the spring until the snap ring can be removed.





8. Remove the snap ring (A). Then remove the special tools (B), spring retainer (C), return spring.





9. For 3rd and 4th clutch: Wrap a shop rag around the clutch drum (A), and apply air pressure to the fluid passage to remove the piston (B). Place a finger tip on the other end while applying air pressure.

Clutch Inspection

1ST/2ND CLUTCH





NOTE: There are two types of spring retainer, you may find either type in the clutch assembly. Some spring retainers have seal lips, and do not have O-rings. The seal lip is undetachable from the spring retainer.





3RD/4TH CLUTCH

Clutch Reassembly

Special Tools Required
- Clutch spring compressor attachment 07LAE-PX40100 Clutch spring compressor attachment 07HAE-PL50101
- Clutch spring compressor bolt assembly 07GAE-PG40200 or 07GAE-PG4020A
- Clutch compressor attachment 07ZAE-PRP0100

Note these items during reassembly:
- Clean all parts thoroughly in solvent or carburetor cleaner, and dry them with compressed air.
- Blow out all passages.
- Apply ATF to all parts before assembly.





1. Inspect the check valve (A) on the 3rd and 4th clutch pistons (B); if it's loose, replace the piston.





2. Install new O-rings (A) on the piston (B) and the spring retainer (1st and 2nd clutches).

NOTE: Some spring retainers of the 1st and 2nd clutch have seal lips and do not have O-rings.





3. Install the piston (A) in the clutch drum (B). Apply pressure and rotate to ensure proper seating. Lubricate the piston O-ring with ATF before installing.

NOTE: Do not pinch the O-ring by installing the piston with too much forte.





4. Install the return spring (A) and spring retainer (B), and position the snap ring (C) on the retainer.





5. Install the special tools on the 3rd/4th clutch assembly.





6. Be sure the special too (A) is adjusted to have full contact with the spring retainer (B) on the 3rd and 4th clutches.





7. Set the special tool (A) on the spring retainer (B) of the 1st and 2nd clutches in such a way that the special tool work on the clutch return spring (C).





8. If either end of the special tool is set over an area of the spring retainer, which is unsupported by the return spring, the retainer may be damaged.





9. Compress the return spring.





10. Install the snap ring (A).
11. Remove the special tools.





12. Install the disc spring in the 1st, 3rd, and 4th clutches in the direction shown.

NOTE: The 2nd clutch does not have a disc spring.

13. Soak the clutch discs thoroughly in ATF for a minimum of 30 minutes. Before installing the plates and discs, make sure the inside of the clutch drum is free of dirt and other foreign matter.





14. Starting with a clutch plate, alternately install the clutch plates and discs. Install the clutch end plate (A) with the flat side toward the disc (B).





15. Install the snap ring (A) with a screwdriver (B).





16. Set a dial indicator (A) on the clutch end plate (B).
17. Zero the dial indicator with the clutch end plate lifted up to the snap ring (C).





18. Release the clutch end plate to lower the clutch end plate, then put the special tool on the end plate (A).
19. Press the special tool down with 40 N (4 kgf, 9 lbs) using a force gauge, and read the dial indicator (B). The dial indicator reads the clearance (C) between the clutch end plate and top disc (D). Take measurements in at least three places, and use the average as the actual clearance.





Clutch End Plate-to-Top Disc Clearance:





20. If the clearance is out of the service limit, select a new clutch end plate from the following table.

NOTE: If the thickest clutch end plate is installed, but the clearance is still over the service limit, replace the clutch discs and clutch plates as a set.





1ST and 2ND CLUTCH END PLATES





3RD and 4TH CLUTCH END PLATES