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 lip.




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




4. Check reverse check force.

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

- 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 sealant 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: Take care not to damage oil seal lip with splines of input shaft while shaft is being inserted Into clutch housing.




b. Install final drive assembly.




c. Install mainshaft assembly.

Note: Take care not to damage oil channel when inserting main- shaft 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 less than the above. Make sure torque is close to the specified range.