Assembly

ASSEMBLY





1. Install striking lever and striking rod.





2. Install selector and retaining pin.





3. Install check ball and reverse check assembly.
- Before installation, rotate striking rod as shown in the figure to avoid interference.





4. Install final drive assembly.
5. Install input shaft and mainshaft with 1st & 2nd shift fork assembly.
- Be careful not to damage input shaft oil seal.





6. Install interlock balls and plunger.





7. Install 3rd & 4th shift fork and bracket, then install 3rd & 4th fork rod, stopper ring and retaining pin.
When installing stopper rings, use snap ring remover and installer (J34305).





8. Install interlock balls.





9. Install 5th shift fork, then install fork rod, stopper ring and retaining pin. When installing stopper rings, use snap ring remover and installer (J3405).





10. Install 5th & reverse check plug, spring and ball.
- Apply sealant to bolt threads. Refer to "Shift Control Components". Major Overhaul





11. Install reverse lock spring on 5th & reverse bracket.
- Pay attention to its direction.





12. Install check ball and reverse lever spring on reverse lever assembly.
- Apply multi-purpose grease to check ball.
- Pay attention to direction of reverse lever spring.





13. Install reverse lever assembly on clutch housing.





14. Install reverse arm shaft and retaining pin.





15. Hook reverse lock spring and reverse lever spring on reverse lever assembly.





16. Mesh 4th gear, then install reverse idler gear and shaft.
- Pay attention to direction of tapped hole.





17. Place magnet on clutch housing.
18. If bearing preload of mainshaft was adjusted, install selected shim(s) into transmission case.





- To aid in installation of transmission case, place shift selector in the 1st and 2nd shift bracket or between 1st and 2nd bracket and 3rd and 4th bracket.

19. Apply sealant to mating surface of transmission case and install it. Refer to Case Components". Major Overhaul
20. Install PNP switch.





21. Apply sealant to threads of check plugs. Install balls, springs and plugs. Refer to Shift Control Components". Major Overhaul
22. After assembly, check that you can shift into each gear smoothly.





23. Measure total turning torque.
Total turning torque (New bearing):
8.8 - 21.6 Nm (90 - 220 kg-cm, 78 - 191 inch lbs.)
- When old bearing is used again, preload will be slightly less than the above. Make sure torque is close to the specified range.