Disassembly and Assembly

NOTE:
- Lubricate all parts with ATF during reassembly.
- Inspect the thrust needle bearing and the needle bearing for galling and rough movement.
- Before installing the O-rings, wrap the shaft splines with tape to prevent damage to the O-rings.
- Install the conical spring washer in the direction shown.



NOTE: Lubricate all parts with ATF assembly.





1. Assemble the parts below on the secondary shaft.





2. Measure the clearance between the 38 x 56.5 mm splined washer and cotters with a feeler gauge.
- Standard: 0.07 - 0.15 mm (0.003 - 0.006 inch).

NOTE: Take measurements in at least three places, and use the average as the actual clearance.

3. If the clearance is out of tolerance, remove the splined washer, and measure the thickness.





4. Select and install a new splined washer, then recheck.
5. After replacing the splined washer, make sure that the clearance is within tolerance.
6. Remove the 27 x 47 x 5 mm thrust washer from the mainshaft.





7. Assemble the parts below on the secondary shaft.

NOTE: Do not assemble the O-rings during inspection.





8. Set the dial indicator to the 2nd gear as shown.





9. Hold the 27 x 47 x 5 mm thrust washer against the clutch assembly, and measure the 2nd gear axial clearance while moving the 2nd gear.
- Standard: 0.07 - 0.15 mm (0.003 - 0.006 inch).

NOTE: Take measurements in at least three places and use the average as the actual clearance.

10. If the clearance is out of tolerance, remove the 37 x 55 mm thrust shim and measure the thickness.





11. Select and install a new thrust shim, then recheck.
12. After replacing the thrust shim, make sure that the clearance is within tolerance.
13. Be sure to install the 27 x 47 x 5 mm thrust washer on the mainshaft.