Assembly

CASE COMPONENTS

Assembly


CASE COMPONENTS

1.Install main drive gear assembly, mainshaft assembly, counter gear assembly and reverse idler shaft assembly. Refer to "Gear Components" in assembly.
2.Install fork rods and shift forks. Refer to "Shift Control Components" in assembly.





3.Install oil gutter to transmission case.





4.Install counter front bearing to transmission case.

CAUTION:
Apply multi-purpose grease to counter front bearing.





5.Apply recommended sealant to mating surface of transmission case as shown.
-Use Genuine Silicone RTV or the equivalent. Recommended Chemical Products And Sealants.

CAUTION:
Remove old sealant adhering to the mating surfaces. Also remove any moisture, oil, or foreign material adhering to both mating surfaces.





6.Install transmission case to adapter plate assembly.





7.Install snap ring to main drive gear bearing using suitable tool.

CAUTION:
Do not reuse snap ring.





8.Tighten baffle plate nut to the specified torque. Refer to "Case
Components" in assembly.





9.Tighten baffle plate bolt to the specified torque. Refer to "Case
Components" in assembly.





10.Install front cover oil seal to front cover using Tool.
Tool number: KV-38102100 (J-25803-01)
Dimension (A): 8.55 - 9.55 (0.336 - 0.376 in)

CAUTION:
- Do not reuse front cover oil seal.
- Apply multi-purpose grease onto oil seal lip.
- When installing, do not incline front cover oil seal.
11.Install front cover according to the following.





a.Install front cover gasket and front cover to transmission case.

CAUTION:
Do not reuse front cover gasket.
b.Temporarily tighten 2 bolts in the positions shown.
c.Temporarily tighten remaining 9 bolts.





d.Tighten bolts to the specified torque in order as shown. Refer to
Transmission Assembly.

CAUTION:
Do not reuse bolts (A) shown.





12.Install washer to withdrawal lever ball pin, and then install it to front cover. Tighten withdrawal lever ball pin to the specified torque. Transmission Assembly





13.Install counter end bearing to OD gear case using suitable tool [32 mm (1.26 in) dia.].
Dimension (A): 0.5 - 1.5 (0.020 - 0.059 in)

CAUTION:
- Do not reuse counter end bearing.
- Apply gear oil to counter end bearing.
- Install counter end bearing with maker stamp at upper side.





14.Install rear oil seal (1) to OD gear case using Tool (A).
Tool number: ST-33200000 (J-26082)

Dimension (H1): -0.5 - 0.5 mm (-0.020 - 0.020 in)

CAUTION:
When installing, do not incline rear oil seal.
(B): Seal lip





15.Apply recommended sealant to mating surface of rear extension as shown.
-Use Genuine Silicone RTV or the equivalent. Recommended Chemical Products And Sealants.

CAUTION:
Remove old sealant adhering to the mating surfaces. Also remove any moisture, oil, or foreign material adhering to both mating surfaces.





16.Install OD gear case to adapter plate, and then tighten bolts to the specified torque in order as shown. Transmission Assembly.





17.Install check shift pin and pivot bolt to transmission case, and then tighten them to the specified torque. Transmission Assembly.

CAUTION:
Do not reuse check shift pin and pivot bolt.





18.Install return spring plunger, return spring and return spring plug to OD gear case, and then tighten return spring plug to the specified torque. Transmission Assembly.

CAUTION:
- Do not reuse return spring plug.
- Apply gear oil to return spring plunger.
19.Install PNP switch and back-up lamp switch according to the following.





a.Install plunger to OD gear case.
b.Apply recommended sealant to threads of PNP switch and back-up lamp switch.
-Use Genuine Silicone RTV or the equivalent. Recommended Chemical Products And Sealants.
c.Install PNP switch and back-up lamp switch to OD gear case, and tighten them to the specified torque. Transmission Assembly.





20.Install clips to PNP switch and back-up lamp switch.

CAUTION:
- Thread harness through the notch of clip.





- Thread the harness as shown.
21.Install striking arm according to the following.





a.Install striking arm to striking rod assembly.
b.Install retaining pin to striking arm using suitable tool.

CAUTION:
Do not reuse retaining pin.
22.Install control housing according to the following.





a.Install gasket and control housing to OD gear case.

CAUTION:
Do not reuse gasket.
b.Tighten bolts to the specified torque in order as shown. Refer to
Transmission Assembly.





23.Install gasket to drain plug, and then install it to transmission case. Tighten drain plug to the specified torque. Transmission Assembly.

CAUTION:
Do not reuse gasket.





24.Install gasket to filler plug, and then install it to transmission case. Tighten filler plug to the specified torque. Transmission Assembly.

CAUTION:
- Do not reuse gasket.
- After oil is filled, tighten filler plug to specified torque.