Transmission Reassembly

Reassembly





1. Install the differential assembly in the clutch housing.





2. Install the spring washer (A) and washer (B) over the ball bearing (C). Note the installation direction of the spring washer (A).
3. Tape the splines of the mainshaft (E) with vinyl tape to protect the seal. Insert the mainshaft and countershaft (F) into the shift forks (D), and install them as an assembly.





4. Install the reverse idler gear (A) and reverse idler gear shaft (B) in the clutch housing (C).





5. Install the reverse shift fork (A) in the clutch housing (B) with the 5th/reverse shift piece pin positioned in the slot of the reverse shift fork. Make sure the steel ball (C) is in the proper position.





6. Install the oil gutter plate in the transmission housing.





7. Select the proper size 78 mm shim (A) according to the measurements made during the Mainshaft Thrust Clearance Adjustment. Install the oil guide plate (B) and 78 mm shim into the transmission housing (C).





8. Remove the dirt and oil from the transmission housing sealing surface. Apply liquid gasket (P/N 08718-0001) to the sealing surface. Be sure to seal the entire circumference of the bolt holes to prevent oil leakage.

NOTE: If 20 minutes have passed after applying liquid gasket, reapply it and assemble the housings. Allow it to cure at least 20 minutes after assembly before filling the transmission with oil.

9. Install the 14 x 20 mm dowel pins.





10. Set the tapered cone ring (A). 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 snap ring (A). Release the snap ring so it seats in the groove of the countershaft bearing.





12. Check that the snap ring (A) is securely seated in the groove of the countershaft bearing.
Dimension (1) as installed: 3.6 - 6.3 mm (0.14 - 0.25 inch)
13. Apply liquid gasket (P/N 08718-0001) to the threads of the 32 mm sealing bolt (B), and install it on the transmission housing.





14. Install the front transmission hanger (A) and the rear transmission hanger (B), then tighten the bolts in a crisscross pattern in several steps.
8 x 1.25 mm bolts: 27 Nm (2.8 kgf-cm, 20 ft. lbs.)
10 x 1.25 mm bolts: 47 Nm (4.8 kgf-cm, 35 ft. lbs.)





15. Install the 5/16 in steel balls (A), 26 mm (1.02 inch) length springs (B), washers (C) and setting screws (D).
16. Install the reverse idler gear shaft bolt (E) with a new washer (F).
17. Install the shift arm cover assembly.
18. Shift the transmission through all the gears before installing it.