Disassembly and Assembly

BASIC SUBASSEMBLY SEPARATION
1. Remove back-up light switch.
Torque: 40 N.m (30 ft. lbs.)
2. Remove speedometer driven gear.
Remove the lock plate set bolt and driven gear.
Torque: 13 N.m (108 inch lbs.)
3. Remove clutch housing.
Remove the 9 bolts and clutch housing.
Torque: 37 N.m (27 ft. lbs.)
4. Remove control shift lever retainer.
a. Remove the 6 bolts.
Formed In Place Gasket (FIPG), Three Bond 1281 Or Equivalent.
Torque: 18 N.m (13 ft. lbs.)
b. Remove the retainer and oil baffle plate.
5. Remove 2 restrict pins and gaskets.

INSTALLATION HINT: Install the black pin on the reverse gear/5th gear side.

Torque: 40 N.m (30 ft. lbs.)





6. Remove extension housing.
a. Remove the shift lever housing set bolt.
Torque: 39 N.m (29 ft. lbs.)
b. Remove the 9 bolts from the extension housing.
Torque: 37 N.m (27 ft. lbs.)
c. Using a plastic hammer, carefully tap the housing.
d. Disengage the shift and select lever from the shift head.
e. Pull out the extension housing.
FIPG, Three Bond 1281 or equivalent.





7. Remove front bearing retainer and bearing snap ring.
a. Remove the 7 bolts.
Sealant: THREE BOND 1344, LOCTITE 242 or equivalent.
Torque: 25 N.m (18 ft. lbs.)
b. Remove the front bearing retainer.
FIPG, Three Bond 1281 or equivalent.
c. Using a snap ring expander, remove the 2 snap rings.





8. Separate intermediate plate from transmission case.
a. Using a plastic hammer, carefully tap the transmission case.
b. Pull the transmission case from the intermediate plate.

INSTALLATION HINT: Align each bearing outer race and each shift fork shaft end with the case holes.

FIPG, Three Bond 1281 or equivalent.





9. Mount intermediate plate in vise.
a. Use the 2 long clutch housing bolts, plate washers and suitable nuts, as shown.

REMOVAL NOTICE: Increase or decrease plate washers so that the bolt tip does not protrude from the nut.

b. Mount the intermediate plate in a vise.
10. Remove the 2 bolts and oil separator.
Torque: 18 N.m (13 ft. lbs.)
11. Remove front magnet.





12. Remove locking ball and spring.
a. Using a hexagon wrench, remove the 4 straight screw plugs.
Sealant: THREE BOND 1344, LOCTITE 242 or equivalent.
Torque: 25 N.m (18 ft. lbs.)
b. Using a magnetic finger, remove the 3 springs and balls.





13. Remove shift fork, shift fork shaft and reverse idler gear.
a. Remove the No.1 and No.2 shift forks set bolt.
Torque: 20 N.m (14 ft. lbs.)
b. Remove the bolt and reverse idler gear shaft stopper.
Torque: 25 N.m (18 ft. lbs.)
c. Remove the reverse idler gear and shaft with the snap ring.
d. Remove the No.1 shift fork and shaft.





e. Using a magnetic finger, remove the No.1 and No.2 interlock pins.

INSTALLATION HINT: Apply MP grease to the No.1 and No.2 interlock pins.

f. Using 2 screwdrivers and a hammer, tap out the No.2 shift fork shaft snap ring.
g. Remove the No.2 shift fork and shaft.





h. Using a magnetic finger, remove the No.3 interlock pin.

INSTALLATION HINT: Apply MP grease to the No.3 interlock pin.





i. Using a pin punch and hammer, drive out the No.3 shift fork pin.
j. Using a hexagon wrench, remove the plug.
Torque: 25 N.m (18 ft. lbs.)
k. Using a magnetic finger, remove the spring and ball.





l. Pull out the No.4 shift fork shaft.
m. Remove the interlock pin.

INSTALLATION HINT: Apply MP grease to the pin.

n. Remove the No.3 shift fork, fork shaft and reverse shift arm with the snap ring.

INSTALLATION HINT: Align the No.3 shift fork with the No.3 hub sleeve groove, put the reverse shift arm into the pivot of bearing retainer and align the reverse shift arm shoe with the reverse idler gear groove.





14. Remove speedometer drive gear.
Using a screwdriver, pry out both ends of the clip and Remove the drive gear.





15. Inspect counter 5th gear thrust clearance.
Using a feeler gauge, measure the counter 5th gear thrust clearance.

Standard Clearance: 0.10-0.41 mm (0.0039-0.0161 inch)
Maximum Clearance: 0.46 mm (0.0181 inch)





16. Remove counter rear bearing, spacer, counter 5th gear and needle roller bearing.
a. Using a snap ring expander, remove the snap ring.

INSTALLATION HINT: Select a snap ring that will allow minimum axial play.

Snap Ring Mark: Thickness
Mark 1: 1.90-1.95 mm (0.0748-0.0768 inch)
Mark 2: 1.96-2.01 mm (0.0772-0.0791 inch)
Mark 3: 2.02-2.07 mm (0.0795-0.0815 inch)
Mark 4: 2.08-2.13 mm (0.0819-0.0839 inch)
Mark 5: 2.14-2.19 mm (0.0843-0.0862 inch)
Mark 6: 2.20-2.25 mm (0.0866-0.0886 inch)
Mark 7: 2.26-2.31 mm (0.0890-0.0909 inch)





b. Using SST 09950-40010, remove the rear bearing, spacer, 5th gear and bearing.

REMOVAL NOTICE: Be careful not to catch the output shaft rear bearing roller on the counter 4th gear.

c. Remove the spacer.





INSTALLATION HINT:
^ Install the counter 5th gear with the 5th gear gaps aligned with the synchronizer cone ring pin.
^ Using a socket wrench and hammer, drive in the bearing.
^ When driving in the bearing, support the counter shaft in front with a 1.4-2.3 kg (3-5 lbs.) hammer or equivalent.





17. Remove synchronizer ring assembly with No.3 hub sleeve and No.3 clutch hub.
a. Remove the synchronizer ring assembly with the No.3 hub sleeve from the No.3 clutch hub.





b. Remove the spacer.
c. Using 2 screwdrivers and a hammer, tap out the snap ring.

INSTALLATION HINT: Select a snap ring that will allow minimum axial play.

Snap Ring Mark: Thickness
Mark 2: 2.06-2.11 mm (0.0811-0.0831 inch)
Mark 3: 2.12-2.17 mm (0.0835-0.0854 inch)
Mark 4: 2.18-2.23 mm (0.0858-0.0878 inch)
Mark 5: 2.24-2.29 mm (0.0882-0.0902 inch)





d. Using SST 09950-40010 remove the No.3 clutch hub.





INSTALLATION HINT:
^ Using SST 09316-60011 (09316-00011, 09316-00071) and a hammer, drive in the No.3 clutch hub.
^ When installing the No.3 clutch hub, support the counter shaft in front with a 1.4-2.3 kg (3-5 lbs.) hammer or equivalent.

18. Remove rear magnet.





19. Remove output shaft rear bearing and 5th gear.
a. Using 2 screwdrivers and a hammer, tap out the snap ring.

INSTALLATION HINT: Select a snap ring that will allow minimum axial play.

Mark 8: 2.31-2.36 mm (0.0909-0.0929 inch)
Mark 9: 2.37-2.42 mm (0.0933-0.0953 inch)
Mark 10: 2.43-2.48 mm (0.0957-0.0976 inch)
Mark 11: 2.49-2.54 mm (0.0980-0.1000 inch)
Mark 12: 2.55-2.60 mm (0.1004-0.1024 inch)
Mark 13: 2.61-2.66 mm (0.1028-0.1047 inch)
Mark 14: 2.68-2.73 mm (0.1055-0.1075 inch)
Mark 15: 2.74-2.79 mm (0.1079-0.1098 inch)





b. Using SST 09312-20011 (09313-0030, 09313-0040, 09313-0050), remove the rear bearing and 5th gear.





INSTALLATION HINT: Using SST 09312-20011 (09313-00010, 09313-00030, 09313-00040, 09313-00050), install the 5th gear and rear bearing.





20. Remove reverse gear.
a. Using a snap ring expander, remove the snap ring.

INSTALLATION HINT: Select a snap ring that will allow minimum axial play.

Mark 5: 2.25-2.30 mm (0.0886-0.0906 inch)
Mark 11: 2.30-2.35 mm (0.0906-0.0925 inch)
Mark 12: 2.35-2.40 mm (0.0925-0 0945 inch)
Mark 13: 2.40-2.45 mm (0.0945-0.0965 inch)
Mark 14: 2.45-2.50 mm (0.0965-0.0984 inch)
Mark 15: 2.50-2.55 mm (0.0984-0.1004 inch)
Mark 16: 2.55-2.60 mm (0.1004-0.1024 inch)
Mark 17: 2.61-2.66 mm (0.1028-0.1047 inch)
Mark 18: 2.67-2.72 mm (0.1051-0.1071 inch)
Mark 19: 2.73-2.78 mm (0.1075-0.1094 inch)
Mark 20: 2.79-2.84 mm (0.1098-0.1118 inch)
Mark 21: 2.85-2.90 mm (0.1122-0.1142 inch)
Mark 22: 2.91-2.96 mm (0.1146-0.1165 inch)
Mark 23: 2.97-3.02 mm (0.1169-0.1189 inch)





b. Using SST 09950-40010, remove the reverse gear.





INSTALLATION HINT: Using SST 09312-20011 (09313-00030, 09313-00040, 09313-00050), install the reverse gear.

21. Remove rear bearing retainer.
a. Using a Torx socket wrench (T40), unscrew the 4 Torx screws and Remove the rear bearing retainer.
Torque: 18 N.m (13 ft. lbs.)
b. Using a snap ring expander, remove the 2 snap rings.

INSTALLATION HINT: Be sure the snap ring is flush with the intermediate plate surface.





22. Remove output shaft and counter gear from intermediate plate.
a. Remove the output shaft, input shaft and counter gear as a unit from the intermediate plate by pulling on the counter gear and tapping on the intermediate plate with a plastic hammer.
b. Remove the input shaft from the output shaft.





INSTALLATION HINT:

^ Before installing the output shaft, use SST 09950-60010 (09951-00510), 09950-70010 (09951-07150) to Remove the counter gear center bearing outer race.

^ Install the outer race After installing the counter gear.
^ Install the output shaft into the intermediate plate by pulling on the output shaft and tapping on the intermediate plate.





INSTALLATION HINT:

^ Apply gear oil to the needle roller bearing.
^ Install the needle roller bearing to the input shaft.
^ Install the input shaft and counter gear together.
^ Using SST 09316-60011 (09316-00011) and a hammer, install a new counter gear center bearing outer race.

^ Be careful not to damage the bearing rollers.





23. If necessary, replace speedometer driven gear oil seal.
a. Using SST 09921-00010, remove the oil seal.
b. Coat the lip of oil seal with MP grease.
c. Using SST 09201-10000 (09201-01080), 09950-70010 (09951-07150), drive in a new oil seal.
Drive in depth: 25 mm (0.98 inch)

BASIC SUBASSEMBLY REASSEMBLY
Reassembly is in the reverse order of separation.

HINT: Coat all of the sliding and rotating surfaces with gear oil before assembly.