Part 1

TRANSFER ASSEMBLY


Disassembly and Assembly


COMPONENTS





















DISASSEMBLY

Rear Case





1. Remove the rear case bolts.





2. Remove the rear case from the center case.
3. Remove the dust cover using suitable tool.





4. Remove the rear oil seal using suitable tool.

CAUTION:





Do not damage rear case.
5. Remove the breather tube.

Front Case
1. Remove the rear case assembly. Overhaul.
2. Remove the lock pin nut.





3. Remove the lock pin using suitable tool.
4. Remove the shift lever.





5. Remove the side oil seal from the front case using suitable tool.

CAUTION:
Do not damage front case or shift cross.





6. Remove the check plug, check spring and check ball.
7. Remove the wait detection switch.





8. Remove the self-lock nut from the companion flange using suitable tool.





9. Put a matching mark on top of the front drive shaft thread in line with the mark on the companion flange.

CAUTION:
Use paint to make the matching mark on the front drive shaft thread. Never damage the front drive shaft.





10. Remove the companion flange using suitable tool.





11. Remove the center case bolts, harness bracket and air breather.
12. Remove the filler plug and gasket.





13. Separate the center case from the front case. Then remove the center case from the front case by prying it up using suitable tool.

CAUTION:
Do not damage the mating surfaces.





14. Remove the shift rod components together with the 2-4 sleeve and L-H sleeve.
15. Remove the shift cross from the front case, using shift rod (A).





16. Remove the 2-4 sleeve and L-H sleeve from the 2-4 fork and LH fork respectively.





17. Drive out the retaining pin from the shift rod using suitable tool.





18. Remove the L-H fork, 2-4 fork, shift fork spring and fork guide from the shift rod.





19. Remove the input oil seal from the front case using suitable tool.

CAUTION:
Do not damage front case or sun gear.





20. Remove the snap ring from the sun gear.

CAUTION:
Do not damage front case or sun gear.





21. Remove the sun gear assembly and planetary carrier assembly from the front case using Tool.

Tool number : ST35300000 ( - )






22. Remove the snap ring and internal gear using suitable tool.





23. Remove the front oil seal using suitable tool.

CAUTION:
Do not damage front case.





24. Remove the snap ring from the front case.





25. Remove the input bearing from the front case using Tool.

Tool number : ST33200000 (J-26082)






26. Remove the snap ring from the planetary carrier assembly using suitable tool.





27. Remove the sun gear assembly from the planetary carrier assembly.





28. Remove the snap ring from the sun gear assembly using suitable tool.





29. Remove the carrier bearing from the sun gear using Tools.

Tool number
A: ST35300000 ( - )
B: ST30031000 ( - )






30. Remove the needle bearing from the sun gear using Tool.

Tool number : ST33710000 ( - )






31. Remove the metal bushing from the sun gear using Tools.

Tool number
A: ST33710000 ( - )
B: ST35325000 ( - )
C: KV381054S0 (J-34286)


Center Case
1. Remove the rear case assembly. Overhaul.
2. Remove the front case assembly. Overhaul.





3. Hold the front drive shaft with one hand and tap to remove the front drive shaft with the drive chain.

CAUTION:
Do not tap drive chain.





4. Remove the front drive shaft front bearing using Tools.

Tool number
A: ST33052000 ( - )
B: ST30031000 ( - )






5. Remove the front drive shaft rear bearing using Tools.

Tool number
A: ST33052000 ( - )
B: ST30031000 ( - )






6. Remove the neutral-4LO and ATP switches.





7. Remove the bolts and main oil pump cover.





8. Remove the outer gear, inner gear and main oil pump housing from the center case.





9. Remove the seal ring from the main oil pump cover.





10. Remove the stem bleeder from the bleed hole.





11. Remove the snap ring and washer holder from the mainshaft.





12. Remove the C-rings from the mainshaft using suitable tool.





13. Set the center case on the press stand. Remove the mainshaft from the center case.





14. Remove the snap ring from the mainshaft using suitable tool.





15. Remove the thrust needle bearing from the press flange.





16. Press the press flange until the snap ring is out of place using
Tools.

Tool number
A: ST22452000 (J-34335)
B: ST30911000 ( - )
C: KV31103300 ( - )






17. Remove the snap ring from the mainshaft using suitable tool.





18. Remove the press flange from the mainshaft.





19. Remove the return spring assembly from the clutch hub.





20. Remove each plate from the clutch drum.





21. Remove the snap ring from the mainshaft.