Part 1 of 2
DISASSEMBLY
1. Remove the drain plug and filler plug.
1. Remove the drain plug (1) and gasket.
2. Remove the filler plug (2) and gasket.
2. Remove the clutch release bearing and shift fork.
1. Remove the clutch release bearing (3) from the front cover.
2. Remove the split pin (4). Remove the shaft from the under. Remove the shift fork (5).
3. Remove the switch.
1. Remove backup light switch (6) and gasket.
2. Remove 3rd and 4th switch (7) and gasket.
3. Remove 1st and 2nd switch (8) and gasket.
4. Remove the clutch housing.
1. Remove the 9 bolts.
2. Using a plastic hammer, carefully tap the clutch housing.
5. Remove gear control box and gasket.
1. Remove the 6 bolts, gear control box and gasket.
6. Remove transfer adapter.
1. Using a hexagon wrench, remove the plug (1).
2. Using a pin punch and hammer, drive out the slotted spring pin (2).
3. Using the M8 x 1.25 bolt, remove the gear control rod.
NOTE: Turn the M8 bolt a few times, before remove the gear control rod.
4. Remove the 10 bolts and clamp.
5. Using a plastic hammer, tap the transfer adapter.
NOTE:
^ Be careful not to lose the pin.
^ Cover the mainshaft splines with adhesive tape.
This will prevent damage to the oil seal lip.
7. Disassemble the transfer adapter assembly.
1. Using a torx socket wrench (T40), remove the plug.
2. Using a pin punch and hammer, drive out the slotted spring pin. Remove the reverse restrict pin.
3. Remove the oil receiver pipe.
4. Remove the oil seal.
5. Using socket hexagon wrench, remove the plug.
8. Remove the front cover.
1. Remove the 8 bolts.
2. Using a plastic hammer, carefully tap the front cover.
9. Remove the front cover oil seal.
1. Mount the front cover through the aluminum plate in a vise.
2. Using screwdriver, remove oil seal (1).
10. Remove the transmission case.
1. Using a snap ring expander, remove the 2 snap rings (1)(2).
2. Using a plastic hammer, carefully tap the transmission case.
11. Mount the intermediate plate.
1. Mount the intermediate plate through the aluminum plate in a vise.
12. Remove the slotted spring pin.
1. Using a pin punch and hammer, drive out the pin from the arm.