Component Parts Removal

Components - Part 1:

Components - Part 2:

1. REMOVE RELEASE FORK, BEARING BACK-UP LIGHT SWITCH AND SPEEDOMETER DRIVEN GEAR




2. REMOVE RELEASE BEARING RETAINER
3. REMOVE SELECTING BELLCRANK




4. REMOVE TRANSMISSION CASE COVER




5. MEASURE FIFTH GEAR THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance.

Standard clearance: 0.20 - 0.40 mm (0.0079 - 0.0157 in.)
Maximum clearance: 0.45 mm (0.0177 in.)




6. MEASURE FIFTH GEAR OIL CLEARANCE
Using a dial indicator, measure the oil clearance.

Standard clearance: 0.009 - 0.050 mm (0.0004 - 0.0020 in.)
Maximum clearance: 0.07 mm (0.0028 in.)




7. REMOVE NO.1 AND NO.2 LOCK BALL ASSEMBLIES
a. Loosen the lock nut and remove the No.1 lock ball.




b. Using SST, remove the No.2 lock ball.
SST 09313-30021




8. REMOVE SHIFT AND SELECT LEVER ASSEMBLY




9. REMOVE OUTPUT SHAFT LOCK NUT
a. Unstake the nut.
b. Engage the gear double meshing.




c. Remove the lock nut.

HINT: The lock nut has LH threads.

d. Disengage the gear double meshing.




10. REMOVE NO.3 HUB SLEEVE ASSEMBLY AND NO.3 SHIFT FORK
a. Using two screwdrivers and a hammer, tap out the snap ring.
b. Remove the shifting key retainer.
c. Remove the bolt from No.3 shift fork.




d. Using the three case cover set bolts, tighten the tree bolts a little at a time and remove No.3 hub sleeve assembly and shift fork.

11. REMOVE FIFTH GEAR, SYNCHRONIZER RING, NEEDLE ROLLER BEARINGS AND SPACER




12. REMOVE FIFTH DRIVEN GEAR
Using SST, remove the 5th driven gear.
SST 09950-20017




13. REMOVE REAR BEARING RETAINER




14. REMOVE FORK SHAFT SNAP RING
Using two screwdrivers and a hammer, tap out the snap ring.




15. REMOVE BEARING SNAP RINGS
Using snap ring pliers, remove the two snap rings.




16. REMOVE REVERSE IDLER GEAR SHAFT LOCK BOLT




17. REMOVE DIFFERENTIAL SIDE BEARING RETAINER AND SHIM




18. REMOVE TRANSMISSION CASE
a. Remove the seventeen bolts.
b. Using a plastic hammer, tap off the case.




19. REMOVE REVERSE IDLER GEAR AND SHAFT
Pull out the shaft and remove the reverse idler gear and thrust washer.

20. REMOVE REVERSE SHIFT ARM
a. Shift the fork shaft into reverse.
b. Remove the two bolts and pull off the reverse shift arm.




21. REMOVE NO.1, NO.2 SHIFT FORK SHAFTS, NO.1 SHIFT HEAD, NO.1, NO.2 SHIFT FORKS, REVERSE SHIFT FORK, INPUT SHAFT AND OUTPUT SHAFT
a. Using SST, remove the straight screw plug.
SST 09313-30021




b. Using a pin punch and hammer, drive out the slotted spring pin.




c. Remove the input shaft and output shaft together with fork shafts, shift head and shift forks from the transaxle case.




22. SEPARATE NO.1, NO.2 FORK SHAFTS, NO.1 SHIFT HEAD, NO.1, NO.2 SHIFT FORKS, REVERSE SHIFT FORK, INTERLOCK PIN AND NO.2 FORK SHAFT
a. Mount the shift forks to the vise.
b. Drive out the slotted spring pin from No. 1 fork shaft.




c. Separate No.1, No.2 fork shafts, No.1 shift head, No.1, No.2 shift forks, reverse shift fork, interlock pin and No.2 fork shaft.




d. Drive out the slotted spring pin from No. 1 fork shaft.




23. ASSEMBLE NO.1, NO.2 FORK SHAFTS. NO.1 SHIFT HEAD, NO.1, NO.2 SHIFT FORKS, REVERSE SHIFT FORK, INTERLOCK PIN AND NO.2 FORK SHAFT
a. Drive in the slotted spring pin to No.1 fork shaft.




b. Assemble No.1, No.2 fork shafts, No.1 shift head, No.1, No.2 shift forks, reverse shift fork, interlock pin and No.2 fork shaft.




c. Drive in the slotted spring pin to No.1 fork shaft.

24. REMOVE MAGNET FROM TRANSAXLE CASE




25. REMOVE DIFFERENTIAL ASSEMBLY




26. REMOVE TRANSAXLE CASE RECEIVER AND PLATE
a. Remove the two bolts and receiver.
b. Remove the bolt and plate.