Transmission Reassembly

Transmission Reassembly

NOTE:
^ Prior to reassembling, clean all the parts in solvent, dry them, and apply manual transmission fluid (MTF) to any contact surfaces.
^ Place the clutch housing on two pieces of wood thick enough to keep the mainshaft from hitting the workbench.

1. Install the magnet (A) and the differential assembly (B).





2. Install the 28 mm spring washer (A) and the 28 mm washer (B) over the ball bearing (C).





3. Apply tape to the mainshaft (D) splines to protect the seal. Install the mainshaft assembly and the countershaft (E) into the shift forks (F), and install them as an assembly.
4. Install the reverse shift fork.





5. Install the reverse idler gear (A) and the reverse gear shaft (B) by aligning the mark (C) with the reverse gear shaft hole (D).





6. Select the proper size 72 mm shim (A) according to the measurements made during the Mainshaft Thrust Clearance Adjustment. Install the oil gutter plate (B), the oil guide plate M, and the 72 mm shim into the transmission housing (C).





7. Clean any dirt and oil from the transmission housing sealing surface.
8. Apply liquid gasket, P/N 08718-0001, evenly to the mating surface of the transmission housing and the clutch housing. Install the component within 5 minutes of applying the liquid gasket.





9. Install the three 14 x 20 mm dowel pins (A).





10. Place the transmission housing over the clutch housing, being careful to line up the shafts.
11. Lower the transmission housing the rest of the way as you expand the 72 mm snap ring (B). Release the snap ring so it seats in the groove of the countershaft bearing.
12. Make sure the 72 mm snap ring is securely seated in the groove of the countershaft bearing.

Dimension (1) as installed: 3.3 - 6.0 mm (0.13 - 0.24 in.)

13. Apply liquid gasket, P/N 08718-0001, evenly to the threads of the 32 mm searing cap (C) mating surface of the transmission housing. Install the component within 5 minutes of applying the liquid gasket.

NOTE:
^ If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes.
^ If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.

14. Install the transmission hanger A, the transmission hanger B, the harness bracket (C), and the 8 mm flange bolts finger tight.





15. Tighten the 8 mm flange bolts in a crisscross pattern in several steps.





16. Clean any dirt or oil from the change lever assembly sealing surface.
17. Apply liquid gasket, P/N 08718-0001, evenly to the mating surface of the charge lever assembly and the transmission housing. Install the component within 5 minutes of applying the liquid gasket.





18. Install the 8 x 14 mm dowel pins (B), change lever assembly (C), and harness bracket A.





19. Apply liquid gasket, P/N 08718-0001, evenly to the mating surface of the threads of the inter lock bolt (D) and transmission housing. Install the component within 5 minutes of applying the liquid gasket.

NOTE:
^ If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes.
^ If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.

20. Install the drain plug (A) and 10 mm flange bolt (B) with new sealing washers (C). Install the filler plug (D) finger-tight.





21. Apply MTF to the new O-ring (E). Then install the new O-ring, and output shaft (countershaft) speed sensor (F).
22. Install the detent bolts (A), the springs, and steel balls with new washers (B). Then install the transmission hanger (C).





23. Apply liquid gasket, P/N 08718-0001 evenly to the threads of the back-up light switch (D) mating surface of the transmission housing. Install the component within 5 minutes of applying the liquid gasket.

NOTE:
^ If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes.
^ If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.

24. Install the 20 mm bolt (A) and new 20 mm washer (B).