Assembly

ASSEMBLY





1. Install striking rod, lever and interlock.
^ When inserting striking rod into clutch housing, tape edges of striking rod to avoid damaging oil seal lip.





2. Install reverse check sleeve assembly.
3. Install check balls, reverse check spring and reverse check plug.





4. Check reverse check force.
Reverse check force: 4.9 - 7.4 Nm (50 - 75 kg-cm, 43 - 65 inch lbs.)
^ If not within specification, select another check plug having a different length and reinstall it.
Available reverse check plugs: Refer to Application and ID.
5. Install selected reverse check plug.
^ Apply locking sealant to thread of plug before installing it.





6. Install check ball plug, shift check ball and check spring.
7. Install oil pocket.
8. Install gear components onto clutch housing.





a. Install final drive assembly.





b. Install input shaft assembly with bearing retainer, mainshaft assembly and reverse idler gear.
^ Be careful not to damage oil seal lip with splines of input shaft while shaft is being inserted into clutch housing.
^ Be careful not to damage oil channel when inserting mainshaft into clutch housing.





c. Install input shaft front bearing retainer.





9. Apply grease to shifter caps, then install it to control bracket. Install control bracket with 1st & 2nd shift fork.





^ Ensure control bracket is seated correctly on clutch housing.
10. Install 3rd & 4th and 5th shift forks.





11. Insert fork shaft.
^ Apply multi-purpose grease to support spring before installing.
12. Install reverse idler spacer.





13. Apply recommended sealant to mating surface of clutch housing.





14. Install transmission case on clutch housing.





15. Install mainshaft front bearing snap ring.





16. Tap mainshaft with a soft hammer to ensure mainshaft rear bearing snap ring contacts the surface of transmission case.





17. Select case cover using the following procedure.
a. Measure distance between case cover fitting surface and mainshaft rear bearing outer race.
Mainshaft rear bearing end play: 0 - 0.1 mm (0 - 0.004 inch)
b. Select case cover so that clearance "C" will be specified clearance.
Case cover: Refer to Application and ID.





18. Install O-ring and case cover on transmission case. Apply recommended sealant to mating surface of transmission case.