Transmission Reassembly

Transmission Reassembly

NOTE:
^ Prior to reassembling, clean all the parts in solvent, dry them, and apply MTF to any contact surfaces.
^ Place the clutch housing on two pieces of wood thick enough to keep the mainshaft from hitting the workbench.

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





2. Install the 36 mm spring washer (A) and 26 mm washer (B) over the ball bearing (C). Note the installation direction of the spring washer.





3. Apply tape on the mainshaft (D) spline to protect the seal. Install the mainshaft assembly and countershaft assembly (E) into the shift forks (F), and install them as an assembly.
4. Install the reverse idler gear (A) and the reverse gear shaft (B).





5. Install the reverse shift fork.





6. Select the proper size 52 x 62 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 the 52 x 62 mm shim into the transmission housing (C).





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

NOTE: Do not install the transmission housing if too much time has passed after applying the liquid gasket (for P/N 08718-0002, no more than 4 minutes, for all others, no more than 5 minutes). Instead, remove the old residue, and reapply the liquid gasket.





8. Install the two 14 x 20 mm dowel pins (A).





9. Set the tapered cone ring (B) as shown. Place the transmission housing over the clutch housing, being careful to line up the shafts.
10. Lower the transmission housing the rest of the way as you expand the 69 mm snap ring (C). Release the snap ring so it seats in the groove of the countershaft bearing.
11. Make sure the 69 mm snap ring is securely seated in the groove of the countershaft bearing.





12. Apply liquid gasket (P/N 08718-0002) to the threads of the 32 mm sealing cap (D), and install it on the transmission housing.
13. Install the 8 mm flange bolts finger-tight.





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





15. 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 too much time has passed after applying the liquid gasket (for P/N 08718-0002, no more than 4 minutes, for all others, no more than 5 minutes). Instead, remove the old residue, and reapply the liquid gasket.





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





17. Install the drain plug (A), output shaft (countershaft) speed sensor (B), and new O-ring (C). Install the filler plug (D) finger-tight.





18. Install the detent bolts (A), the springs, and the steel balls with new washers (B).





19. Install the 20 mm bolt (C) and new 20 mm washer (D).
20. Install the new washer (A), the back-up light switch (B), and the transmission hanger (C).





21. Install the air cleaner housing bracket (A) and the harness bracket (B).