Part 2
ASSEMBLY(continued)
Shift Control Components
1. Install 5th-6th shift fork to the 5th-6th coupling sleeve.
2. Install 5th-6th fork rod (reversal side) to the 5th-6th shift fork.
3. Using a pin punch [6 mm (0.24 inch) dia.] to tap the retaining pin into the 5th-6th shift fork.
CAUTION: Do not reuse retaining pin.
4. Install 5th-6th fork rod to the adapter plate.
5. Install 5th-6th fork rod bracket to the 5th-6th fork rod.
6. Using a pin punch [6 mm (0.24 inch) dia.] to tap the retaining pin into the 5th-6th fork rod bracket.
CAUTION: Do not reuse retaining pin.
7. Install 5th-6th control lever to the adapter plate and then tighten mounting bolts to the specified torque. Refer to MT-24, Shift Control Components.
CAUTION: Set the projection upward.
8. Install check balls to the adapter plate.
CAUTION: Apply lithium-based grease check ball.
9. Install reverse shift fork to the reverse coupling sleeve.
10. Install reverse fork rod to the reverse shift fork.
11. Using a pin punch [6 mm (0.24 inch) dia.] to tap the retaining pin into the reverse shift fork.
CAUTION: Do not reuse retaining pin.
12. Install interlock pin and interlock plunger to the adapter plate.
CAUTION: Apply lithium-based grease check ball.
13. Install 1st-2nd shift fork to the 1st-2nd coupling sleeve.
14. Install 1st-2nd fork rod to the 1st-2nd shift fork.
15. Using a pin punch [6 mm (0.24 inch) dia.] to tap the retaining pin into the 1st-2nd shift fork.
CAUTION: Do not reuse retaining pin.
16. Install 3rd-4th shift fork to the 3rd-4th coupling sleeve.
17. Install 3rd-4th fork rod (reversal side) to 3rd-4th shift fork.
18. Using a pin punch [6 mm (0.24 inch) dia.] to tap the retaining pin into the 3rd-4th shift fork (reversal side).
CAUTION: Do not reuse retaining pin.
19. Install interlock pin and check balls to the adapter plate.
CAUTION: Apply lithium-based grease check ball.
20. Install 3rd-4th fork rod to the adapter plate.
21. Install 3rd-4th fork rod bracket to the 3rd-4th fork rod.
22. Using a pin punch [6 mm (0.24 inch) dia.] to tap the retaining pin into the 3rd-4th fork rod bracket.
CAUTION: Do not reuse retaining pin.
23. Install check ball, check ball spring into the adapter plate, apply liquid gasket to the check ball plug threads, and tighten check ball plug to the specified torque. Refer to MT-24, Shift Control Components.
^ Use Genuine Silicone RTV or equivalent.
CAUTION: Apply lithium-based grease check ball.
24. Install 3rd-4th control lever to the adapter plate, and then tighten mounting bolts to the specified torque. Refer to MT-24, Shift Control Components.
CAUTION:
^ Make sure the top and bottom are oriented correctly.
25. Install check balls, check ball springs into the adapter plate, apply liquid gasket to the check ball plugs threads, and tighten check ball plugs to the specified torque. Refer to MT-24, Shift Control Components.
^ Use Genuine Silicone RTV or equivalent.
CAUTION: Apply lithium-based grease check ball.
26. Install striking rod to the adapter plate.
27. Install striking lever to the striking rod.
28. Using a pin punch [6 mm (0.24 inch) dia.] to tap the retaining pin into the striking lever.
CAUTION: Do not reuse retaining pin.
29. Install magnet to the adapter plate.
30. Install baffle plate to the adapter plate, and then tighten mounting bolts to the specified torque. Refer to MT-21, Case Components.
Case Components
1. Install counter front bearing to the transmission case.
2. Install oil gutter to transmission case.
3. Install breather to transmission.
CAUTION: Do not reuse breather.
4. Apply liquid gasket to the transmission case adapter plate mounting surface as shown in the figure.
^ Use Genuine Silicone RTV or equivalent.
CAUTION: Complete remove all moisture and oil, etc., from the transmission case and adapter plate mounting surfaces.
5. Place the adapter plate in the transmission case, using a soft hammer to tap the adapter plate to install it into the transmission case.
6. Install snap ring to main drive gear bearing, using snap ring pliers.
CAUTION: Do not reuse snap ring.
7. Tighten baffle plate mounting nut to the specified torque. Refer to MT-21, Case Components.
8. Apply multi-purpose grease to the lip of the front cover oil seal. Using a drift, to install oil seal approximately 8.55 - 9.55 mm (0.336 - 0.376 inch) above from the front cover edge surface.
Tool number: KV38102100 (J-25803-01)
CAUTION:
^ Do not reuse front cover oil seal.
^ When installing, do not incline the front cover oil seal.
9. Install front cover gasket and front cover to the transmission case.
CAUTION: Do not reuse front cover gasket.
10. Temporary tightening 2 bolts in the positions shown in the figure.
11. Temporary tightening remaining 9 bolts.
CAUTION: Four bolts pointed by arrows in the figure are not reusable.
12. Tighten bolts to the specified torque in order as shown on the figure. Refer to MT-21, Case Components.
13. Install washer to the withdrawal lever ball pin and then install it to front cover. Tighten withdrawal lever ball pin to the specified torque. Refer to MT-21, Case Components.
14. Install rear extension oil gutter to rear extension, and then tighten bolt to specified torque. Refer to MT-21, Case Components.
15. Install reverse idler shaft, reverse idler needle bearing, reverse idler gear, and reverse idler thrust washer to the adapter plate.
16. Apply multi-purpose grease to the striking rod oil seal lip, and then using the drift to install striking rod oil seal.
Tool number: ST35291000 ( - )
CAUTION:
^ Do not reuse striking rod oil seal.
^ When installing, do not incline the striking rod oil seal.
17. Apply multi-purpose grease to the lip of the rear oil seal. Using a drift, to install rear oil seal. 1.2 - 2.2 mm (0.047 - 0.087 inch) above from the rear extension edge surface.
Tool number: ST33400001 (J-26082)
CAUTION:
^ Do not reuse rear oil seal.
^ When installing, do not incline the rear oil seal.
18. Apply liquid gasket to the adapter plate rear extension mounting surface as shown in the figure.
^ Use Genuine Silicone RTV or equivalent.
CAUTION: Completely remove all moisture, oil, etc., from the adapter plate and rear extension mounting surfaces.
19. Install rear extension to adapter plate and then tighten mounting bolts to the specified torque in order as shown on the figure. Refer to MT-21, Case Components.
20. Install control lever housing to the rear extension and then tighten mounting bolts to the specified torque. Refer to MT-24, Shift Control Components.
CAUTION: Do not hold control lever housing to prevent bushing of control lever housing from deformation when moving transmission assembly.
21. Install return spring plungers and return springs into the rear extension, apply liquid gasket to the return spring plug threads, and then tighten return spring plug to the specified torque. Refer to MT-24, Shift Control Components.
^ Use Genuine Silicone RTV or equivalent.
CAUTION: The right and left return spring and return spring plunger are different, so make sure they are installed correctly.
22. Install shift check pin as a one unit with the control bracket to rear extension and then tighten mounting bolts to the specified torque. Refer to MT-24, Shift Control Components.
23. Install plunger to the rear extension, and then screwing PNP switch and back-up lamp switch to the rear extension with 1-2 pitches. Apply liquid gasket to the switch threads, and tighten switch to the specified torque. Refer to MT-21, Case Components.
^ Use Genuine Silicone RTV or equivalent.
24. Install retaining pin into the control rod, using a pin punch [6 mm (0.24 inch) dia.].
CAUTION: Do not reuse retaining pin.
25. Install check ball and check select spring into the rear extension.
26. Install rear extension upper cover gasket and rear extension upper cover to rear extension.
CAUTION:
^ Do not reuse rear extension upper cover gasket.
^ Avoid tangling check select spring.
27. Tighten rear extension upper cover bolts to the specified torque in order as shown on the figure. Refer to MT-21, Case Components.