Assembly

REASSEMBLY
1. Install the differential assembly in the clutch housing.





2. Install the spring washer and washer with the angle against the clutch housing.
3. Insert the mainshaft, countershaft, and shift forks into the clutch housing.

NOTE: Before installing the mainshaft, tape the splines to protect the splines and seal from damage.





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





5. 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: Ensure that the steel ball is in the correct position.





6. Install the oil gutter plate in the transmission housing.

NOTE: Select the 78 mm shim according to the measurements obtained for the mainshaft: Adjustments





7. Install the oil guide plate and 78 mm shim into the transmission housing.





8. Apply liquid gasket to the surface of the transmission housing:
- Use liquid gasket (P/N 07818-0001 or 07818-0003).
- Remove any oil or debris from the sealing surfaces.
- Seal the entire circumference of the bolt holes to prevent leakage.
- Housings must be assembled before 20 minutes have elapsed.
- Allow 20 minutes to elapse before filling transmission with oil.

9. Install the 14x20 mm dowel pins.









10. Position the stop ring to align with the 5th gear shift fork, and with the notches in the transmission housing.





11 Lower the transmission housing, and set the snap ring into the groove of the countershaft bearing.





12. Ensure that the snap ring is securely seated in the groove of the countershaft bearing.
Dimension A as installed: 3.6 - 6.3 mm (0.142 - 0.248 in.)


13. Install the 32 mm sealing bolt.

NOTE: Apply liquid sealer to the threads.





14. Install the transmission hangers A and B, then tighten the bolts to specifications in several steps, using a crisscross pattern.





15. Install the reverse idler gear shaft bolt.

16 Install the shift detent steel balls, springs washers and set screws.

NOTE: Always replace set screw washers.

17 Install the shift arm cover assembly.

18. Shift the transmission through all the gears prior to installation.