Basic Subassembly Separation

1. REMOVE RELEASE FORK. BEARING AND SPEEDOMETER DRIVEN GEAR
2. REMOVE BACK-UP LIGHT SWITCH
3. REMOVE CONTROL LEVER HOUSING SUPPORT BRACKET
4. REMOVE SELECTING BELLCRANK




5. REMOVE TRANSMISSION CASE COVER




6. INSPECT 5TH GEAR THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance.

Standard clearance: 0.10 - 0.57 mm (0.0039 - 0.0224 in.)
Maximum thrust clearance: 0.65 mm (0.0256 in.)




7. INSPECT 5TH GEAR RADIAL CLEARANCE
Using a dial indicator, measure the radial clearance.

Standard clearance: 0.015 - 0.058 mm (0.0006 - 0.0023 in.)
Maximum clearance: 0.070 mm (0.0028 in.)

If the clearance exceeds the maximum, replace the gear, needle roller bearing or shaft.




8. REMOVE LOCK BOLT




9. REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY




10. REMOVE LOCK NUT
a. Engage the gear double meshing.
b. Using a hammer and chisel, loosen the staked part of the nut.




c. Remove the lock nut.
d. Disengage the gear double meshing.




11. REMOVE NO.3 HUB SLEEVE ASSEMBLY AND NO.3 SHIFT FORK
a. Using 2 screwdrivers and a hammer. tap out the snap ring.




b. Remove the bolt from No.3 shift fork.
c. Remove No.3 hub sleeve and shift fork.




d. Using SST, remove the 5th gear, No.3 hub, synchronizer ring. needle roller bearings and spacer.
SST 09213-36020




12. REMOVE 5TH DRIVEN GEAR
Using SST and a socket wrench, remove the 5th driven gear.
SST 09213-36020




13. REMOVE REAR BEARING RETAINER




14. REMOVE BEARING SNAP RINGS
Using a snap ring expander, remove the 2 snap rings.

HINT: If it is difficult to remove the snap rings, pull up the shafts.




15. REMOVE REVERSE IDLER GEAR SHAFT LOCK BOLT




16. REMOVE SNAP RING FROM NO.2 SHIFT FORK SHAFT
Using 2 screwdrivers and a hammer, tap out the snap ring.




17. REMOVE PLUGS, SEATS. SPRINGS, BALLS AND LOCK BALL ASSEMBLY
a. Using a hexagon wrench, remove the 3 plugs and lock ball assembly.
b. Using a magnetic finger, remove the 3 seats, springs and balls.




18. REMOVE TRANSMISSION CASE
Remove the 16 bolts, and tap off the case with a plastic hammer.




19. REMOVE REVERSE IDLER GEAR, THRUST WASHER AND SHAFT
Pull out the shaft.




20. REMOVE REVERSE SHIFT ARM BRACKET
Remove the 2 bolts and pull off the bracket.




21. REMOVE SHIFT FORKS AND SHIFT FORK SHAFTS
a. Using 2 screwdrivers and a hammer, tap out the 3 snap rings.




b. Remove the 3 set bolts.




c. Remove the No.2 fork shaft and the shift head.




d. Using a magnetic finger, remove the 2 balls from the reverse shift fork.




e. Remove No.3 fork shaft and the reverse shift fork.
f. Pull out No.1 fork shaft.
g. Remove No.1 and No.2 shift forks.




22. REMOVE INPUT AND OUTPUT SHAFTS TOGETHER FROM TRANSAXLE CASE




23. REMOVE DIFFERENTIAL ASSEMBLY




24. REMOVE MAGNET FROM TRANSAXLE CASE




25. REMOVE NO.3 HUB SLEEVE, SHIFTING KEYS AND SPRINGS FROM NO.2 CLUTCH HUB
Using a screwdriver, remove the 3 shifting keys and springs from the No.2 clutch hub.