Transmission Reassembly

Transmission Reassembly

NOTE: Prior to reassembly, clean all parts in solvent, dry them, and apply MTF to any contact surfaces.

1. Install the magnet (A) and differential assembly (B).

NOTE: Clean the magnet anytime the transmission is disassembled.





2. Install the 28 mm spring washer (A) and the 28 mm washer (B) over the ball bearing (C). Note the installation direction of the spring washer.





3. Apply vinyl tape to the mainshaft splines (D) to protect the seal. Install the mainshaft assembly (E) and the countershaft assembly (F) with the shift fork assembly (G), as an assembly.
4. Install the reverse shift fork (A).





5. Install the reverse idler gear (A) and reverse gear shaft (B) by aligning the mark (C) with the reverse gear shaft hole (D).





6. Install the reverse lock cam.





7. Install the baffle plate (A).





8. Select the proper size 72 mm shim (A) according to the measurements made during the Mainshaft Thrust Clearance Adjustment. Install the oil gutter plate (B), oil guide plate M, and 72 mm shim into the transmission housing (C).





9. Clean any dirt or oil from the transmission housing sealing surface. Apply liquid basket (P/N 08718-0002) to the sealing surface as shown.

NOTE: Do not install transmission housing if 4 minutes or more have passed after applying the liquid gasket. Instead, remove the old residue and reapply the liquid gasket.





10. Install the three 14 x 20 mm dowel pins (A).





11. Set the tapered cone ring (B) as shown. Place the transmission housing on the clutch housing, being careful to line up the shafts.
12. While expanding the 72 mm snap ring (C) of the countershaft ball bearing using the snap ring pliers, push the transmission housing down to start the countershaft ball bearing through the snap ring. Then release the pliers, and push down the housing until it bottoms and the snap ring snaps in place in the countershaft ball bearing snap ring groove.
13. Make sure the 72 mm snap ring is securely seated in the groove of the countershaft bearing.





14. Apply liquid gasket (P/N 08718-0001) to the threads of the 32 mm sealing cap (D), and install it on the transmission housing.
15. Install transmission hangers A and B, and the 8 mm flange bolts, finger-tight.





16. Tighten the 8 mm flange bolts in a crisscross pattern in several steps.





17. Clean any dirt or oil from the change lever assembly sealing surface. Apply liquid gasket (P/N 08718-0002) to the sealing surface.

NOTE: Do not install the change lever assembly if 4 minutes or more have passed after applying the liquid gasket. Instead, remove the old residue and reapply the liquid gasket.





18. Install the 8 x 14 mm dowel pins (A) and the change lever assembly (B).





19. Apply liquid gasket (P/N 08718-0002) to the threads of the interlock bolt (C), and install it on the transmission housing.
20. Install the filler plug (A) with a new washer finger tight, and install the drain plug (B) and 10 mm flange bolt (C) with new sealing washers (D).





21. Install the new O-ring (E), plain washer (F), and output shaft (countershaft) speed sensor (G).
22. Install the detent bolts (A), springs, and steel balls with new sealing washers (B).





23. Install a new 20 mm sealing washer (C), 20 mm bolt (D), and transmission hanger (E).
24. Apply liquid gasket (P/N 08718-0002) to the threads of the back-up light switch (F), and install it in the transmission housing.