Disassembly
Transmission Disassembly
Exploded View-Rear Cover
Exploded View-Transmission Housing
Exploded View-Clutch Housing
Special Tools Required
^ Flange holder 07RAB-TB4010B
^ Adjustable bearing puller, 20-40 mm 07736-A01000B
^ Mainshaft holder 07PAB-001A300
^ Holder handle 07JAB-001020A
Rear Cover Removal
1. Remove the four bolts, and remove the shift lever housing.
2. Lower the shift rod (A), then remove the 8 mm special bolt (B), the spring washer (C), and the shift arm B (D).
3. Remove the 8 mm flange bolts in a criss-cross pattern in several steps.
4. Remove the rear cover (A) and the 14 x 20 dowel pins (B).
5. Remove the shift rod tube and the O-rings from the rear cover.
6. Raise the 27 mm locknut tab from the groove in the secondary shaft.
7. Install the special tool onto the companion flange, and loosen the 27 mm locknut.
8. Remove the 27 mm locknut (A), the spring washer (B), the back-up ring (C), and the O-ring (D).
9. Remove the companion flange (A) using a commercially available bearing puller (B) as shown.
10. Remove the oil seal.
11. Remove the secondary shaft (A) from the rear cover (B) using a press (C) as shown.
12. Remove the ball bearing (D) from the rear cover.
13. Remove the bearing outer race (A) and the shim (B) from the rear cover (C).
14. Remove the bearing outer race (A) from the rear cover (B) using the special tools as shown.
Transmission Housing Removal
1. Remove the oil pump near shaft and oil pump near.
2. Raise the 29 mm locknut tab from the groove in the countershaft.
3. Install the special tool onto the mainshaft spline, and loosen the 29 mm locknut (left-hand threads).
4. Remove the 29 mm locknut and spring washer.
5. Remove the needle bearing (A) using a commercially available bearing puller (B) as shown.
6. Remove the secondary drive gear (A) using a commercially available bearing puller (B) as shown.
7. Remove the 6 mm flange bolts, then remove the oil pump plate (A), spring, steel ball, and oil pump rotors (B).
8. Remove the drain plug (A), the filler plug (B), the 12 mm drain plug (C), washers, the set screws (D), springs, steel balls, and the pick up sensor (E).
9. Remove the set screws (A), springs, steel balls, the back-us light switch (B). and washer.
10. Remove the 8 mm flange bolts in a crisscross pattern in several steps.
11. Remove the transmission housing and the 14 x 20 dowel pins (A).
12. Remove the bearing outer race (A) using the special tool as shown, then remove the shim (B) and the oil guide plate S.
13. Remove the 16 x 26 x 7 mm oil seal from the transmission housing.
14. Remove the circlip (A), then remove the suction guide (B) and the oil pump strainer (C) from the transmission housing.
15. Remove the 82 mm shim(s) (A) and the oil guide plate M.
16. Remove the oil guide tube (A) and the magnet (B).
17. Remove the 8 mm flange bolt and washer, then remove the reverse shaft holder (A), the thrust washer (B), the reverse gear shaft (C), and the needle bearing (D).
18. Remove the 10 mm flange bolt, then remove the 8 x 63 pin (A) and the 1-2 shift levers (B).
19. Remove the 5 x 25 spring pin (B) from the shift arm (A) with a 5 mm pin driver, then remove the shift rod (C).
20. Remove the shift arm (A) from the interlock (D), then remove the select return spring (E) and the 8 x 40 pin (F).
21. Remove the 1-2 shift piece.
22. Remove the 34 mm sealing bolt (A) from the clutch housing.
23. Expand the 68 mm snap ring (B) on the countershaft ball bearing, and remove it from the groove using a pair of snap ring pliers.
24. Remove the mainshaft, countershaft, and the shift forks assembly (C), and remove the 64 mm spring washer, the reverse idler gear (D), thrust washer.
25. Remove the 6 mm flange bolts and the release bearing guide (A).
26. Remove the 8 mm special bolts, the clutch release hanger (B) and the release hanger spring (C).
27. Remove the 6 mm flange bolts and the breather plate (D).
28. Remove the oil seal from the clutch housing.