Component Parts Removal
COMPONENTSPart 1:
Part 2:
1. REMOVE RELEASE FORK, BEARING BACK-UP LIGHT SWITCH AND SPEEDOMETER DRIVEN GEAR
2. REMOVE RELEASE BEARING RETAINER
3. REMOVE SELECTING BELLCRANK
4. REMOVE TRANSMISSION CASE COVER
5. INSPECT FIFTH GEAR THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance.
Standard clearance: 0.20 - 0.40 mm (0.0079 - 0.0157 in.)
Maximum clearance: 0.45 mm (0.0177 in.)
6. INSPECT FIFTH GEAR OIL CLEARANCE
Using a dial indicator, measure the oil clearance.
Standard clearance: 0.009 - 0.050 mm (0.0004 - 0.0020 in.)
Maximum clearance: 0.07 mm (0.0028 in.)
If the clearance exceeds the maximum, replace the gear, needle roller bearing or input shaft
7. REMOVE NO.1 AND NO.2 LOCK BALL ASSEMBLIES
a. Loosen the lock nut and remove the No.1 lock ball.
b. Using SST, remove the No.2 lock ball.
SST 09313-30021
8. REMOVE SHIFT AND SELECT LEVER ASSEMBLY
9. REMOVE OUTPUT SHAFT LOCK NUT
a. Unstake the nut
b. Engage the gear double meshing.
c. Remove the lock nut.
HINT: The lock nut has LH threads.
d. Disengage the gear double meshing.
10. REMOVE NO.3 HUB SLEEVE ASSEMBLY AND NO.3 SHIFT FORK
a. Using two screwdrivers and a hammer, tap out the snap ring.
b. Remove the shifting key retainer.
c. Remove the bolt from the No.3 shift fork.
d. Using the three case cover set bolts, tighten the tree bolts a little at a time and remove the No.3 hub sleeve assembly and shift fork.
11. REMOVE FIFTH GEAR, SYNCHRONIZER RING, NEEDLE ROLLER BEARINGS AND SPACER
12. REMOVE FIFTH DRIVEN GEAR
Using SST, remove the 5th driven gear.
SST 09950-20017
13. REMOVE REAR BEARING RETAINER
14. REMOVE FORK SHAFT SNAP RING
Using two screwdrivers and a hammer, tap Out the snap ring.
15. REMOVE BEARING SNAP RINGS
Using a snap ring expander, remove the two snap rings.
HINT: If it is difficult to remove the snap rings, pull up the shafts.
16. REMOVE REVERSE IDLER GEAR SHAFT LOCK BOLT
17. REMOVE DIFFERENTIAL SIDE BEARING RETAINER AND SHIM
18. REMOVE TRANSMISSION CASE
a. Remove the seventeen bolts.
b. Using a plastic hammer, tap off the transmission case.
19. REMOVE REVERSE IDLER GEAR AND SHAFT
Pull out the shaft and remove the reverse idler gear and thrust washer.
20. REMOVE REVERSE SHIFT ARM
a. Shift the fork shaft into reverse.
b. Remove the two bolts and pull off the reverse shift arm.
21. REMOVE NO.1 SHIFT FORK SHAFT, NO.1 SHIFT HEAD, NO.1 AND NO.2 SHIFT FORKS, INPUT SHAFT AND OUTPUT SHAFT
a. Drive out the slotted spring pin from No.1 fork shaft
b. Remove the input shaft and output shaft together with No.1 fork shaft, shift head and shift forks from the transaxle case.
22. SEPARATE NO.1 FORK SHAFT, NO.1 SHIFT HEAD, NO.1 AND NO.2 SHIFT FORKS
a. Mount the shift forks to the vise.
b. Using a pin punch and hammer, drive out the slotted spring pin from No.1 fork shaft.
c. Separate the No.1 shift fork, shaft, No.1 shift head, No.1 and No.2 shift fork.
23. REMOVE REVERSE SHIFT FORK AND INTERLOCK PIN
24. REMOVE NO.2 FORK SHAFT
a. Using SST, remove the straight screw plug.
SST 09313-30021
b. Using a pin punch and hammer, drive out the slotted spring pin.
c. Pull out the shaft.
25. REMOVE DIFFERENTIAL ASSEMBLY
26. REMOVE TRANSAXLE CASE RECEIVER AND PLATE
a. Remove the two bolts and receiver.
b. Remove the bolt and plate.
27. REMOVE MAGNET FROM TRANSAXLE CASE
INSPECTION OF COMPONENT PARTS
1. INSPECT SYNCHRONIZER RING OF FIFTH GEAR
a. Check for wear or damage.
b. Turn the ring and push it in to check the bearing action.
c. Using a feeler gauge, measure the clearance between the synchronizer ring back and the gear spline end.
Minimum clearance: 0.6 mm (0.024 in.)
If the clearance is less than the minimum, replace the synchronizer ring.
2. INSPECT CLEARANCE OF NO.3 SHIFT FORK AND NO.3 HUB SLEEVE
Using a feeler gauge, measure the clearance between the hub sleeve and shift fork.
Maximum clearance: 1.0 mm (0.039 in.)
If the clearance exceeds the maximum, replace the shift fork or hub sleeve.
3. IF NECESSARY, REPLACE INPUT SHAFT FRONT BEARING
a. Remove the bolt and transaxle case receiver.
b. Using SST, pull out the bearing.
SST 09308-00010
c. Using SST, press in a new bearing.
SST 09310-35010
d. Install the transaxle case receiver and torque the bolt.
Torque: 75 kg-cm (65 in.-lb, 7.4 N.m)
4. IF NECESSARY, REPLACE OUTPUT SHAFT FRONT BEARING
a. Remove the bolt and bearing lock plate.
b. Using SST, pull out the bearing.
SST 09308-00010
c. Using SST, press in a new bearing.
SST 09310-35010
d. Install the bearing lock plate and torque the bolt.
Torque: 185 kg-cm (13 ft-lb, 19 N.m)
5. IF NECESSARY, REPLACE INPUT SHAFT FRONT OIL SEAL
a. Using a screwdriver, pry out the oil seal.
b. Using SST, drive in a new oil seal.
SST 09608-20012 (09608-00080, 09608-03020)
Drive in depth: 0 - 0.5 mm (0 - 0.020 in.)
c. Coat the lip of the oil seal with MP grease.
6. IF NECESSARY, REPLACE SPEEDOMETER DRIVEN GEAR OIL SEAL
a. Using SST, pull out the oil seal.
SST 09921-00010
b. Coat the lip of oil seal with MP grease.
c. Using SST, drive in a new oil seal.
SST 09201-60011
Drive in depth: 19 mm (0.75 in.)
7. IF NECESSARY. REPLACE REVERSE RESTRICT PIN
a. Using SST, remove the straight screw plug.
SST 09313-30021
b. Using a pin punch and hammer, drive out the slotted spring pin.
c. Replace the reverse restrict pin.
d. Drive in the slotted spring pin.
e. Apply sealant to the plug threads.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
f. Using SST, install the straight screw plug.
SST 09313-30021
Torque: 130 kg-cm (9 ft-lb, 13 N.m)