Transmission Installation
INSTALLATION1. Set the release fork, release bearing and release shaft to transmission.
2. Install the transmission.
NOTE:
^ Make sure the main shaft spline part is inserted completely.
^ Make sure the rear side of engine is lowered.
Tightening torque: 50 Nm (5.1 kgf-cm, 36.9 ft. lbs.)
3. Move the transmission to the right side, then install the joint COMPL bolt, stay bolt and reverse check cable.
Tightening torque:
T1: 11.8 Nm (1.2 kgf-cm, 8.7 ft. lbs.)
T2: 32 Nm (3.3 kgf-cm, 23.6 ft. lbs.)
4. Install the front crossmember and rear crossmember.
NOTE: Rotate the ST (ENGINE SUPPORT ASSY) turn buckle clockwise (to make longer the ST) and lift up the rear side of engine to facilitate installation.
Tightening torque:
T1: 70 Nm (7.1 kgf-cm, 51.6 ft. lbs.)
T2: 140 Nm (14.3 kgf-cm, 103 ft. lbs.)
5. Lower the vehicle and install the fixing bolt.
Tightening torque: 50 Nm (5.1 kgf-cm, 36.9 ft. lbs.)
6. Make sure the release bearing is installed completely.
NOTE:
^ Push the release fork to operating cylinder side until you hear a "click" sound. Pull the release fork to engine side. Setting is completed if the release fork does not contact the case.
^ Make sure the boot cover is firmly set.
7. Install the pitching stopper bracket.
Tightening torque: 41 Nm (4.2 kgf-cm, 30.2 ft. lbs.)
8. Install the pitching stopper.
Tightening torque:
T1: 50 Nm (5.1 kgf-cm, 36.9 ft. lbs.)
T2: 58 Nm (5.9 kgf-cm, 42.8 ft. lbs.)
9. Install the clutch operating cylinder.
Tightening torque: 41 Nm (4.2 kgf-cm, 30.2 ft. lbs.)
NOTE: Check that the clutch hose is routed properly.
10. Install the starter assembly.
Tightening torque: 50 Nm (5.1 kgf-cm, 36.9 ft. lbs.)
11. Install the transmission and body ground cable.
12. Connect the connector located on the upper side of transmission.
13. Lift-up the vehicle, and then install the drive shaft.
14. Using the ST, install the spring pin of front drive shaft.
ST 398791700 REMOVER
NOTE: Align each chamfered part of front drive shaft and axle drive shaft spring pin hole, and assemble them. Then insert the spring pin.
15. Install the ball joint of transverse link to housing.
Tightening torque: 50 Nm (5.1 kgf-cm, 36.9 ft. lbs.)
16. Install the stabilizer nut.
Tightening torque: 45 Nm (4.6 kgf-cm, 33.2 ft. lbs.)
NOTE: Discard the loosened self-locking nut and replace with a new one.
17. Install the propeller shaft.
18. Install the center exhaust pipe.
19. Install the rear exhaust pipe and muffler.
20. Install the under cover.
21. Install the intercooler assembly.
22. Connect the battery ground cable to battery.