Transmission Reassembly
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 PAB-0010300 or PAB 0010000
^ 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), release hanger spring (C), and the breather plate (D).
3. Install the thrust washer (A) and 64 mm spring washer (B).
4. Install the reverse idler gear (C), mainshaft, countershaft, and shift fork assemblies (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 8X40 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 5 x 25 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), reverse gear shaft (B), thrust washer (C), and reverse shaft holder (D), then install the washer and 8 mm flange bolt.
13. Install the oil guide tube (A) and magnet (B).
14. Install the oil guide plate M and 82 mm shim(s) (A).
15. Install the oil pump strainer (A), suction guide (B), and circlip (C).
16. Install the 16 x 26 x 7 mm oil seal (A) as shown.
17. Install the oil guide plate S and 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. Be sure to seal the entire circumference of the bolt holes to prevent oil leakage.
NOTE:
^ If 5 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.
19. Install the 14 x 20 dowel pins (A), transmission housing (B), 8 mm flange bolts, transmission hanger (C), and transmission hanger A (D).
20. Tighten the 8 mm flange bolts in a crisscross pattern in several steps as shown.
8 x 1.25 mm 27 Nm (2.8 kgf-m, 20 ft. lbs.)
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 back-up light switch (C).
23. Install the washers (A), drain plug (B), filler plug (C), 12 mm drain plug (D), and 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, steel ball (A), spring (B), 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.
Torque 172 -> 0 -> 172 Nm (17.5 -> 0 -> 17.5 kgf-m, 127 -> 0 -> 127 ft. lbs.)
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
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 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), back-up ring (B), spring washer (C), and 27 mm locknut (D).
8. Install the special tool on the companion flange, then tighten the 27 mm locknut the to the specified value.
Torque 162 -> 0 -> 162 Nm (16.5 -> 0 -> 16.5 kgf-m, 119 -> 0 -> 119 ft. lbs.)
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. Be sure to seal the entire circumference of the bolt holes to prevent oil leakage.
NOTE:
^ If 5 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.
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), spring washer (C), and 8 mm special bolt.
15. Install the shift lever housing.