Disassembly
1. Remove 4WD switch and take out steel ball.
2. Remove 5 bolts and then remove gear shift lever case.
3. After removing bolt of select return system, take out spring, steel ball and pin.
4. By hammering Special Tool (A) 09922-X5811, drive spring pin out of reduction shift yoke.
NOTE:
- Pin may drop into case when driven out. Therefore, take it out when case is disassembled.
- After spring pin is removed, yoke may be either taken out.
5. Remove 15 rear ease bolts and then separate case by using Special Tool (B) 09912-34510.
NOTE: To separate case, use special tool at 4 points in turn and make opening wider evenly.
6. Remove circlip by using screwdrivers and hammer, then pull out speedometer drive gear.
7. Remove circlip for bearing and pull out bearing No. 2 by combination of Special Tool (C) 09921-57810 and (D) 09927-18410.
8. Pull out sprocket bush and needle bearing from output rear shaft.
9. Remove sprocket and then remove drive chain.
NOTE: Watch out for steel ball which comes off from shaft when bush is pulled out so as not to lose it.
10. Remove counter shaft plate bolt from front case, and counter shaft plate will come off.
11. Remove front case by removing its 9 bolts.
12. Remove input gear needle bearing. Remove counter gear shaft together with needle bearings, spacer, washers and steel balls from case.
NOTE:
- Watch out for steel balls which come out from between shaft and washers (front and rear) so as not to lose them.
- Check friction ring lip for damage and wear. Replace if necessary.
- Neither O-ring nor friction ring should be remove unless absolutely necessary. If removed, use new parts for reinstallation. Removed ones should not be reused.
13. Remove O-ring from shaft and then remove friction ring from shaft, using a proper size rod and press.
14. Remove locating spring bolt with washer, spring and ball for reduction shift. Remove rubber plug as well.
15. Pull out reduction shift shaft together with fork and sleeve.
NOTE: For this removal, be sure to place front drive fork shaft at 4WD position.
16. Remove locating spring bolt with washer, spring and ball for front drive shift.
17. Pull out front drive shift fork & shaft, sleeve and hub all to0ether.
NOTE: Watch out for interlock steel ball which comes out from between 2 shift shafts so as not to lose it. If it doesn't come out, remove rubber plug and take it out.
18. Using plastic hammer, drive out output rear shaft assembly with bearing. Output low gear and reduction clutch hub also come off as they are installed to shaft.
19. Pull off circlip from shaft and remove reduction clutch hub, output low gear and needle bearing.
20. Using puller and press, remove bearing No. 1 from shaft.
21. Remove oil seal from center case.
22. Using plastic hammer, drive out output front shaft together with bearings.
CAUTION: If oil seal remains in front case, be careful not to damage oil seal by hitting. Use drive punch for hammering.
23. Take off bearings from shaft by using press and puller. Removal of front side bearing requires Special Tool (E) 09925-98221 additionally as shown.
24. To remove needle bearing from center case, combine Special Tools (F) 09913-84510 and (G) 09941-64511 as shown in the figure and press them.
25. Remove oil seal from rear case. And then, using same Special Tools (F) 09913-84510, (G) 09941-64511 and press as in above step, remove needle bearing from rear case.
CAUTION: Be careful not to damage oil seal, if it remains in rear case.
26. Using Special Tool (H) 09900-06108, remove circlip of input gear bearing from front case.
NOTE: Be sure to use right tool to ensure proper work.
27. Using plastic hammer, drive gear out of case.
28. Remove circlip of input gear by using Special Tool (I) 09900-06107.
29. Remove bearing by using puller and press with Special Tool (J) 09951-76010.
NOTE: Use metal pad for this removal, or gear spline may get damaged.
30. With spring on front drive fork shaft compressed, remove circlip and then remove fork and spring.
31. Remove oil gutter with wrench.