Disassembly

DISASSEMBLY





1. Before removing transmission case, remove bolts, check plugs, springs and check balls as shown left.
- Be careful not to lose check balls.
2. Remove transmission case.





3. Remove PNP switch.





4. Mesh 4th gear, and then remove reverse idler shaft and reverse idler gear.





5. Pull out retaining pin.





6. Remove reverse lever spring and reverse lock spring from reverse lever assembly.





7. Remove reverse arm shaft while rotating it.





8. Remove reverse lever assembly and check ball.
- Be careful not to lose check ball.





9. Remove 5th & reverse check plug, spring and ball.
- Be careful not to lose check ball.





10. Remove stopper rings and retaining pins from 5th and 3rd & 4th fork rods.
11. Remove 5th and 3rd & 4th fork rods. Then remove forks and brackets.
12. Remove both input and mainshafts with 1st & 2nd fork and fork rod as a set.





13. Remove final drive assembly.
- Always withdraw mainshaft straight out. Failure to do so can damage resin oil channel on clutch housing side.





14. Remove reverse check assembly and check ball.
- Be careful not to lose check ball.








15. Remove retaining pin and detach the selector.





16. Remove drain plug for convenience in removing retaining pin which holds striking lever to striking rod.





17. Remove retaining pin and then withdraw striking lever and striking rod.