Reassembly

1. Install the differential assembly in the clutch housing.





2. Install the shift fork, then drive the spring pin through the 5th/reverse shift piece.

NOTE: Tape the mainshaft spline before installation.

3. Install the spring washer with the angle against the clutch housing as shown.





4. Insert the mainshaft and countershaft into the shift forks and install them as an assembly.





5. Install the reverse idler gear and reverse idler gear shaft in the clutch housing.





6. Install the reverse shift fork in the clutch housing with the 5th/reverse shift piece pin positioned in the slot of the reverse shift fork.

NOTE:
- Check that the steel ball is in the proper position.
- Select the thrust shim according to the measurements.





7. Install the oil guide plate and 78 mm thrust shim into the transmission housing.
8. Install the oil gutter plate in the transmission housing.

NOTE: Bend the hook of the oil gutter plate into the hole on the transmission housing.





9. Install the 28 mm sealing bolt.

NOTE: Apply liquid gasket (P/N 08718-0001) to the threads.





10. Apply liquid gasket to the transmission housing mating surface of the clutch housing.

NOTE
- Use liquid gasket (P/N 08718-0001).
- Remove the dirt oil from the sealing surface.
- Apply liquid gasket on the central part of the sealing surface.
- Seal the entire circumference of the bolt hole to prevent oil leakage.
- If 20 minutes have passed after applying liquid gasket, reapply it and assemble the housings.
- Refill the oil after 30 minutes after replacement.

11. Install the 14 x 20 mm dowel pins.





12. Set the stopper ring as shown. Place the transmission housing over the clutch housing, being careful to line up the shafts.

NOTE: Set the long arm of 5th shift fork with the hook of stopper ring.

13. Lower the transmission housing with the snap ring plier and set the snap ring in the groove of the countershaft bearing.





14. Install the 32 mm sealing bolt.

NOTE: Apply liquid gasket (P/N 08718-000) to the threads.





15. Tighten the bolts in a criss-cross pattern in several steps as shown.
16. Install the reverse idler gear shaft bolt.





17. Install the steel balls, springs, washers, and setting screws.
18. Install the shift arm cover assembly.