Part 2
ASSEMBLY (continued)Front Case
1. Install the carrier bearing to the sun gear using Tools.
Tool number
A: ST30911000 ( - )
B: KV31103300 ( - )
2. Install the new snap ring to the sun gear assembly using suitable tool.
CAUTION: Do not reuse snap ring.
3. Apply [1][2]ATF to the circumference of the new metal bushing and install it to the sun gear assembly using Tool.
Tool number: ST35300000 ( - )
Dimension A: 7.7 - 8.3 mm (0.303 - 0.327 in)
CAUTION:
^ Do not reuse metal bushing.
^ Apply [1][2]ATF to metal bushing before installing.
4. Apply [1][2]ATF to the new needle bearing and install it to the sun gear assembly using Tool.
Tool number: ST33220000 ( - )
Dimension B: 62.5 - 63.1 mm (2.461 - 2.484 in)
CAUTION:
^ Do not reuse needle bearing.
^ Apply [1][2]ATF to needle bearing before installing.
5. Install the sun gear assembly to the planetary carrier assembly.
6. Install the new snap ring to the planetary carrier assembly.
CAUTION: Do not reuse snap ring.
7. Set the input bearing into the front case and install using Tool.
Tool number: ST30720000 (J-25405)
8. Install the new snap ring into the front case.
CAUTION: Do not reuse snap ring.
9. Install the internal gear with its groove facing the snap ring into the front case. Then secure it with the new snap ring.
CAUTION: Do not reuse snap ring.
10. Install the new front oil seal until it is seated flush with the end face of the front case using Tool.
Tool number: KV38100500 ( - )
CAUTION:
^ Do not reuse oil seal.
^ Apply petroleum jelly to oil seal lip before installing.
11. Install the planetary carrier assembly and sun gear assembly to the front case using Tool.
Tool number: ST33200000 (J-26082)
12. Install the new snap ring to the sun gear.
CAUTION: Do not reuse snap ring.
13. Apply petroleum jelly to the circumference of the new oil seal, and install it to the front case using Tools.
Tool number
A: ST30720000 (J-25405)
B: ST33200000 (J-26082)
Dimension: 4.0 - 4.6 mm (0.157 - 0.181 mm)
CAUTION:
^ Do not reuse oil seal.
^ Apply petroleum jelly to oil seal.
14. Install the fork guide, shift fork spring, 2-4 fork, and L-H fork to the shift rod, and secure them with new retaining pins.
CAUTION: Do not reuse retaining pins.
15. Install the 2-4 sleeve and L-H sleeve to each fork.
16. Install the shift cross to the front case.
17. While aligning the L-H sleeve with the planetary carrier, install the shift rod assembly (A) to the front case.
18. Apply liquid gasket to the entire center case mating surface of the front case assembly as shown.
^ Use Genuine Anaerobic Liquid Gasket or equivalent.
CAUTION: Remove all foreign materials such as water, oil and grease from center case and front case mating surfaces.
19. Install the center case assembly to the front case assembly.
CAUTION: Do not damage mainshaft end.
20. Tap the center case lightly and press-fit the front drive shaft bearing into the front case.
21. Tighten the front case bolts to the specified torque.
CAUTION: Be sure to install air breather hose clamp, connector bracket and harness clip.
22. Install the drain plug with a new gasket.
CAUTION: Do not reuse gasket.
23. Align the matching mark on the front drive shaft with the mark on the companion flange, then install the companion flange.
24. Install a new companion flange self-lock nut. Tighten to the specified torque using Tool.
Tool number: KV40104000 ( - )
CAUTION: Do not reuse self-lock nut.
25. Remove all the sealant from the check plug, switch mounting and front case.
CAUTION: Remove old sealant adhering to mating surfaces. Also remove any moisture, oil, or foreign material adhering to application and mounting surfaces.
26. Install the check ball and check spring to the front case. Apply sealant to the check plug and wait detection switch and install them to the front case. Tighten to the specified torque.
^ Use Genuine Silicone RTV or equivalent.
NOTE: Wait detection switch harness connector is black.
27. Install the new oil seal in the front case using Tool.
Tool number: ST22360002 (J-25679-01)
CAUTION:
^ Do not reuse oil seal.
^ Apply petroleum jelly to seal lip before installing.
28. Install the shift lever to the shift cross.
29. Install the lock pin and lock pin nut. Tighten to the specified torque.
Rear Case
1. Apply petroleum jelly to the circumference of the new rear oil seal. Install the new rear oil seal so that it is flush with the case tip face using Tool.
Tool number: ST30720000 (J-25405)
CAUTION:
^ Do not reuse oil seal.
^ Apply petroleum jelly to seal lip before installing.
2. Apply petroleum jelly to the circumference of the new dust cover. Position the new dust cover using the identification mark as shown.
CAUTION:
^ Do not reuse dust cover.
^ Position the identification mark at the position shown.
3. Install the new dust cover using Tool.
Tool number: KV40105310 ( - )
4. Install the air breather into the rear case.
5. Remove all the sealant from the rear case to center case mating surfaces.
CAUTION: Remove all foreign materials such as water, oil, and grease from center case and rear case mating surfaces.
6. Apply liquid gasket to the entire rear case mating surface of the center case.
^ Use Genuine Anaerobic Liquid Gasket or equivalent.
CAUTION: Do not to allow Liquid Gasket to enter stem bleeder hole.
7. Install the rear case to the center case. Tighten the bolts to the specified torque.