Reassembly
Transmission ReassemblySpecial Tools Required
^ Driver 07749-0010000
^ Attachment, 42 x 47 mm 07746-0010300
^ Attachment, 62 x 68 mm 07746-0010500
^ Driver, 30 mm I.D. 07946-MB00000
^ Attachment, 35 mm I.D. 07965-SA50500
^ Mainshaft holder 07PAB-001A300
^ Attachment,72 x 75 mm 07746-0010600
^ Attachment, 40 x 50 mm I.D. 07LAD-PW50601
^ Driver, 40 mm I.D. 07746-0030100
^ Flange holder 07RAB-TB4010B
^ Holder handle 07JAB-001020A
Transmission Housing Installation
NOTE: Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricate to any contact surfaces.
1. Install the oil seal (A) using the special tools.
2. Install the release bearing guide (A), the clutch release hanger (B), the release hanger spring (C), and the breather plate (D).
3. Install the thrust washer (A) and the 64 mm spring washer (B).
4. Install the reverse idler gear (C), mainshaft, countershaft, and the shift fork assembly (D) with the snap ring pliers, and set the 68 mm snap ring (E) into the groove of the countershaft bearing.
NOTE: Check that the snap ring is securely seated in the groove of the countershaft bearing.
Standard: 0 - 6.93 mm (0 - 0.273 inch)
5. Apply liquid gasket (P/N 08718-0001) to the threads of the 34 mm sealing bolt (F), then install the 34 mm sealing bolt.
6. Install the 1-2 shift piece.
7. install the select return spring (A) and the 8 x 40 pin (B) onto the transmission, then install the interlock (C).
8. Install the shift arm A by aligning the interlock finger and the shift fork grooves.
9. Install the shift rod (A) into the interlock assembly (B) with it recessed hole (C) toward the top of the transmission (D), then install the 5x25 spring pin (E).
10. Install the outer side 1-2 shift lever (A) first, then install the inner side 1-2 shift lever (B).
11. Install the 8 x 63 pin (C), then tighten the 10 mm flange bolt (D).
12. Install the needle bearing (A), the reverse gear shaft (B), the thrust washer (C), and the reverse shaft holder (D), then install the washer and 8 mm flange bolt.
13. Install the oil guide tube (A) and the magnet (B).
14. Install the oil guide plate M and the 82 mm shim(s) (A).
15. Install the oil pump strainer (A), the suction guide (B), and the circlip (C).
16. Install the 16 x 26 x 7 mm oil seal (A) as shown.
17. Install the oil guide plate S and the shim (A), then install the bearing outer race (B) using the special tools as shown.
18. Remove the dirty oil from the transmission housing sealing surface. Apply liquid gasket (P/N 08718-0001) to the sealing surface. Make sure you seal the entire circumference of the bolt holes to prevent oil leakage.
19. Install the 14 x 20 dowel pins (A), the transmission housing (B), 8 mm flange bolts, the transmission hanger (C), and the transmission hanger A (D).
20. Tighten the 8 mm flange bolts in a criss-cross pattern in several steps as shown.
21. Apply liquid gasket (P/N 08718-0001) to the threads of the set screws (A), then install the steel balls and springs.
22. Install the washer (B) and the back-up light switch (C).
23. Install the washers (A), the drain plug (B), the filler plug (C), the 12 mm drain plug (D), and the pick up sensor (E) with a new O-ring.
24. Apply liquid gasket (P/N 08718-0001) to the threads of the set screws (F), then install the steel balls and springs.
25. Install the oil pump outer rotor S, the steel ball (A), the spring (B), and the oil pump plate (C).
26. Install the secondary drive gear (A) on the countershaft using the special tool as shown.
27. Install the needle bearing (A) on the countershaft using the special tool as shown.
28. Install the spring washer and 29 mm locknut.
29. Install the special tool on the mainshaft, then tighten the 29 mm locknut (left-hand threads) to the specified value.
30. Stake the 29 mm locknut tab into the groove.
31. Install the oil pump gear and oil pump gear shaft.
Rear Cover Installation
NOTE: Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricate to any contact surfaces.
1. Install the bearing outer race (A) using the special tools as shown.
2. Install the shim and the bearing outer race into the rear cover using the special tools as shown.
3. Install the secondary shaft assembly into the rear cover.
4. Install the new ball bearing (A) using the special tools and the old bearing (B).
5. Install the oil seal (A) using the special tools.
6. Install the companion flange (A) using the special tool as shown.
7. Install the O-ring (A), the back-up ring (B), the spring washer (C), and the 27 mm locknut (D).
8. Install the special tool on the companion flange, then tighten the 27 mm locknut the to the specified value.
9. Stake the 27 mm locknut tab into the groove.
10. Install the shift rod pipe and O-rings.
11. Remove the dirty oil from the rear cover sealing surface. Apply liquid gasket (P/N 08718-0001) to the sealing surface. Make sure you seal the entire circumference of the bolt holes to prevent oil leakage.
12. Install the 14 x 20 dowel pins (A), rear cover assembly (B), harness bracket (C), harness clamp (D), and 8 mm flange bolts.
13. Tighten the 8 mm flange bolts in a crisscross pattern in several steps.
14. Lower the shift rod (A), then install the shift arm B (B), the spring washer (C), and 8 mm special bolt.
15. Install the shift lever housing.