Assembly

1. Install striking rod, lever and interlock.

Note: When inserting striking rod into clutch housing, tape edges of striking rod to avoid damaging oil seal's lip if it hits against oil seal.




2. Install reverse check sleeve assembly.
3. Install check balls, reverse check spring and check plug.




4. Check reverse check force.

Reverse check force:
4.9 - 7.4 N-m
(50 - 75 kg-cm, 43 - 65 in-lb)

If not within specification, select another check plug having a different length and reinstall it.

Reverse check plug: [1][2]Mechanical Specifications

5. Install selected reverse check plug.

Note: Apply locking sealer to thread of plug before installing it.




6. Install check ball plug, shift check ball and check spring.
7. Install oil pocket.




8. Install gear components onto clutch housing.
a. Install input shaft assembly and reverse idler gear.

Note: Use care not to damage oil seal's lip by splines of input shaft while shaft is being inserted into clutch housing.




b. Install final drive assembly.




c. Install mainshaft assembly.

Note: Use care not to damage oil channel when inserting mainshaft into clutch housing.




9. Apply grease to shifter caps, then install it to control bracket. Install control bracket with 1st & 2nd shift fork.
10. Install 3rd & 4th and 5th shift forks.




11. Insert fork shaft.

Note: Apply multi-purpose grease to support spring before installing.

12. Install reverse idler spacer.




13. Apply recommended sealant to mating surface of clutch housing.




14. Install transmission case on clutch housing.




15. Measure total turning torque.

Total turning torque (New bearing):
5.9 - 13.7 N-m
(60 - 140 kg-cm, 52 - 122 in-lb)

Note: When old bearing is used again, turning torque will be slightly lower than that indicated above. Check turning torque to see if it is not far from specified range.