Disassembly

Disassembly




1. Remove case cover.




2. Remove mainshaft bearing snap ring.




3. Remove transmission case while slightly tilting it to prevent 5th shift fork from interfering with transmission case.




4. Draw out reverse idler spacer and fork shaft.




5. Remove 5th and 3rd & 4th shift forks.

Note: Be careful not to lose shifter cap.




6. Remove control bracket with 1st & 2nd shift fork.




7. Remove gear components from clutch housing.
a. Remove input shaft front bearing retainer securing bolts.




b. Remove input shaft with bearing retainer, mainshaft assembly and reverse idler gear.

Note: Always withdraw mainshaft straight out. Failure to do so can damage resin oil channel on clutch housing side.

Note: Do not draw out reverse Idler shaft from clutch housing because these fillings will be loose.

Note: When removing input shaft, be careful not to scratch oil seal lip with shaft spline.

c. Remove final drive assembly.




8. Remove oil pocket, shift check ball, check spring and check ball plug.




9. Drive retaining pin out of striking lever with tool, then remove striking rod, striking lever and striking interlock.

Note: Select a position where retaining pin does not interfere with clutch housing when removing retaining pin.




Note: Be careful not to damage oil seal lip, when removing striking rod. If necessary, tape edges of striking rod.




10. Remove reverse check plug, then detach reverse check spring and check balls.

Note: If the smaller ball does not come out, remove it together with check sleeve assembly.

11. Remove check sleeve assembly.