Assembly of Transmission

1. INSERT NO.1 AND NO.2 CLUTCH HUBS INTO HUB SLEEVES
a. Install the clutch hub and shifting keys to the hub sleeve.
b. Install the shifting key springs under the shifting keys.

CAUTION: Install the key springs positioned so that their end gaps are not in line.




2. INSTALL THIRD GEAR AND NO.2 CLUTCH HUB ON OUTPUT SHAFT
a. Apply gear oil to the shaft.
b. Place the synchronizer ring on the gear and align the ring slots with the shifting keys.




c. Using a press, install the 3rd gear and No.2 clutch hub.




3. INSTALL SNAP RING




a. Select a snap ring that will allow minimum axial play.




b. Using snap ring pliers, install the snap ring.




4. MEASURE THIRD GEAR THRUST CLEARANCE
Using a feeler gauge, measure the 3rd gear thrust clearance.

Standard clearance: 0.10 - 0.25 mm (0.0039 - 0.0098 in.)

5. INSTALL SECOND GEAR AND NO.1 CLUTCH HUB
a. Apply gear oil to the shaft and needle roller bearing.




b. Place the synchronizer ring on the gear and align the ring slots with the shifting keys.
c. Install the needle roller bearing in the 2nd gear.




d. Using a press, install the 2nd gear and No. 1 clutch hub.




6. INSTALL LOCKING BALL AND FIRST GEAR ASSEMBLY
a. Install the locking ball in the shaft.
b. Apply gear oil to the needle roller bearing.
c. Assemble the 1st gear, synchronizer ring, needle roller bearing and inner race.




d. Install the assembly on the output shaft with the synchronizer ring slots aligned with the shifting keys and turn the inner race to align it with the locking ball.




7. INSTALL OUTPUT SHAFT CENTER BEARING
Using SST and a press, install the bearing on the output shaft with the outer race snap ring groove toward the rear.

NOTE: Hold the 1st gear inner race to prevent it from falling.

SST 09506-30012




8. MEASURE FIRST AND SECOND GEAR THRUST CLEARANCE
Using a feeler gauge, measure the 1st and 2nd gear thrust clearance.

Standard clearance: 0.10 - 0.25 mm (0.0039 - 0.0098 in.)




9. INSTALL OUTPUT SHAFT TO INTERMEDIATE PLATE
a. Before installing the output shaft, use SST to remove the counter gear center bearing outer race.
SST 09608-35014 (09608-06020, 09608-06090)

NOTE: Install the outer race after installing the counter gear.




b. Install the output shaft into the intermediate plate by pulling on the output shaft and tapping on the intermediate plate.




10. INSTALL INPUT SHAFT AND COUNTER GEAR
a. Apply gear oil to the needle roller bearing and install it into the input shaft.
b. Install the input shaft to the output shaft with the synchronizer ring slots aligned with the shifting keys.
c. Install the counter gear.




d. Using SST, install the counter gear center bearing outer race.
SST 09316-60010 (09316-00010)

NOTE: Be careful not to damage the bearing rollers.




11. INSTALL CENTER BEARING RETAINER
a. Using snap ring pliers, install the snap ring.

NOTE: Be sure the snap ring is flush with the intermediate plate surface.




b. Using a torx socket wrench, tighten the torx screws.

Torque: 130 kg-cm (9 ft-lb, 13 N-m)




12. INSTALL REVERSE GEAR
Using SST, install the reverse gear.
SST 09312-20011

NOTE: Turn each SST nut a little at a time in alternate passes.




13. INSTALL SNAP RING




Select a snap ring that will allow minimum axial play and install it on the shaft.




14. INSTALL FIFTH GEAR AND OUTPUT SHAFT REAR BEARING
Using SST, install the 5th gear and rear bearing.
SST 09312-20011

NOTE: Turn each SST nut a little at a time in alternate passes.




15. INSTALL SNAP RING




a. Select a snap ring that will allow minimum axial play.




b. Using a screwdriver and hammer, install the snap ring.
16. INSERT NO.3 CLUTCH HUB INTO HUB SLEEVE




a. Install No.3 clutch hub and the shifting keys to the hub sleeve.
b. Install the shifting key springs under the shifting keys.

CAUTION: Install the key springs positioned so that their end gaps are not in line.




c. Using SST, install the shifting key retainer.
SST 09238-47012




17. INSTALL NO.3 CLUTCH HUB
Using SST, drive in No.3 clutch hub.
SST 09316-60010 (09316-00010, 09316-00070)

NOTE: When installing the clutch hub, support the counter gear in front with a 3 - 5 lb hammer or equivalent.




18. INSTALL SNAP RING




a. Select a snap ring that will allow minimum axial play.




b. Using a screwdriver and hammer, install the snap ring.




19. INSTALL SPACER, SYNCHRONIZER RING, NEEDLE ROLLER BEARINGS AND COUNTER FIFTH GEAR
a. Install the bearing spacer.
b. Apply gear oil to the needle roller bearings.
c. Assemble the counter 5th gear, synchronizer ring and needle roller bearings.




d. Install the counter 5th gear assembly with the synchronizer ring slots aligned with the shifting keys.




20. INSTALL SPACER AND BEARING
a. Install the spacer.
b. Install the bearing with the ball shield toward the rear.
c. Using a hammer and socket wrench, drive in the bearing.

NOTE: When driving in the bearing, support the counter gear in front with a 3 - 5 lb hammer or equivalent.




21. INSTALL SNAP RING




Select a snap ring that will allow minimum axial play and install it on the shaft.




22. INSTALL SPEEDOMETER DRIVE GEAR
a. Install the drive gear clip into the slot.
b. Slide the drive gear with clip and fit the clip into the holes.




23. INSTALL SHIFT FORKS, SHIFT FORK SHAFTS AND REVERSE IDLER GEAR
a. Install the reverse idler gear and shaft.
b. Install No.3 shift fork, fork shaft and reverse shift arm.
1. Coat the pin with MP grease and insert it into the reverse shift arm hole.




2. Insert No.3 shift fork shaft through No.3 shift fork and the reverse shift arm.
3. Align No.3 shift fork with the No.3 hub sleeve groove. Put the reverse shift arm into the pivot of bearing retainer and align the reverse shift arm shoe with the reverse idler gear groove. Install No.3 shift fork shaft to the intermediate plate.
c. Install No.4 shift fork shaft.




1. Push the pin, which was inserted into the reverse shift arm hole, into the groove of No.3 shift fork shaft.




2. Install No.4 shift fork shaft to the intermediate plate over the reverse shift arm.




d. Using a pin punch, drive in the slotted spring pin until it is flush with the fork.




e. Apply MP grease to No.3 interlock pin and install the pin into the intermediate plate hole.
f. Install No.2 shift fork an fork shaft.




1. Apply MP grease to No. 2 interlock pin and install the pin into the shaft hole.




2. Place No.2 shift fork into the groove of No.2 hub sleeve.
3. Install No.2 fork shaft to the shift fork through the intermediate plate.




g. Install the snap ring of No.2 fork shaft.




h. Apply MP grease to No.1 interlock pin and install the pin into the intermediate plate.




i. Install No. 1 shift fork and fork shaft.
1. Install No.1 shift fork into the groove of No.1 hub sleeve.
2. Insert No.1 fork shaft to the shift fork through the intermediate plate.




j. Install the snap ring of No. 1 fork shaft.




k. Install the shift fork set bolts with the lock washers.

Torque: 125 kg-cm (9 ft-lb, 12 N-m)




l. Using pliers, stake the bolts with the lock washers.
24. INSTALL LOCKING BALLS AND SPRINGS




a. Install the balls and springs into each hole.
b. Apply sealant to the plug threads.
Sealant: Part No.08833-00080, THREE BOND 1344. LOCTITE 242 or equivalent




c. Using SST, tighten the four plugs.
SST 09313-30021

Torque: 250 kg-cm (18 ft-lb, 25 N-m)




25. INSTALL REVERSE IDLER GEAR SHAFT STOPPER
Install the reverse idler gear shaft stopper and tighten the bolt.

Torque: 250 kg-cm (18 ft-lb, 25 N-m)




26. REMOVE INTERMEDIATE PLATE FROM VISE
a. Remove the intermediate plate from the vise.
b. Remove the bolts, nuts, plate washers and gaskets.




27. INSTALL TRANSMISSION CASE TO INTERMEDIATE PLATE WITH NEW GASKET
a. Align each bearing outer race and each shift fork shaft end with the case holes.
b. Using a plastic hammer, tap on the case to install it.




28. INSTALL BEARING SNAP RINGS
Using snap ring pliers, install the two snap rings.




29. INSTALL FRONT BEARING RETAINER
a. Install the bearing retainer with a new gasket.
b. Apply sealant to the bolt threads.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
c. Install and torque the bolts.

Torque: 250 kg-cm (18 ft-lb. 25 N-m)

30. INSTALL EXTENSION HOUSING




a. Place a new gasket in position on the intermediate plate.
b. Insert the shift and select lever into the extension housing.




c. Connect the shift and select lever to the shift fork shaft.




d. Install the shift lever housing to the shift and select lever shaft, and push in the extension housing.




e. Install and torque the bolt.

Torque: 400 kg-cm (29 ft-lb, 39 N-m)




31. INSTALL AND TORQUE EXTENSION HOUSING BOLTS

Torque: 375 kg-cm (27 ft-lb, 37 N-m)

32. AFTER INSTALLING EXTENSION HOUSING, CHECK FOLLOWING ITEMS:
a. Check to see that input and output shafts rotate smoothly.
b. Check to see that shifting can be made smoothly to all positions.




33. INSTALL RESTRICT PINS
a. Install the restrict pins together with the gasket.

NOTE: Install the black pin on the reverse gear and 5th gear side.

b. Torque the restrict pins.

Torque: 410 kg-cm (30 ft-lb, 40 N-m)




34. INSTALL CLUTCH HOUSING
a. Install the clutch housing.
b. Install and torque the bolts.

Torque: 375 kg-cm (27 ft-lb, 37 N-m)

35. INSTALL RELEASE FORK AND BEARING
a. Apply molybdenum disulphide lithium base grease to the following parts:
- Release bearing hub inside groove
- Input shaft spline
- Release fork contact surface
b. Apply MP grease to the front surface of the release bearing.




36. INSTALL SHIFT LEVER RETAINER
a. Install the shift lever retainer.
b. Install and torque the bolts.

Torque: 185 kg-cm (13 ft-lb, 18 N-m)

37. INSTALL SPEEDOMETER DRIVEN GEAR
a. Install the speedometer driven gear.
b. Install the bolt with the lock plate.
c. Torque the bolt.
38. INSTALL BACK-UP LIGHT SWITCH
a. Install and torque the back-up light switch.

Torque: 410 kg-cm (30 ft-lb, 40 N-m)

b. Install the wire clamp.
39. INSTALL REAR SPEED SENSOR (w/A.B.S.)