Disassembly of Transmission

1. REMOVE BACK-UP LIGHT SWITCH, REAR SPEED SENSOR (w/ ABS) AND SPEEDOMETER DRIVEN GEAR




2. REMOVE CLUTCH HOUSING FROM TRANSMISSION CASE
Remove the nine bolts and clutch housing from the transmission case.




3. REMOVE SHIFT LEVER RETAINER
a. Remove the six bolts.
b. Remove the shift lever retainer and oil baffle plate.




4. REMOVE RESTRICT PIN
5. REMOVE EXTENSION HOUSING




a. Remove the shift lever housing set bolt.




b. Remove the nine bolts.
c. Using a plastic hammer, tap the extension housing.
d. Disengage the shift and select lever from the shift head.
e. Pull out the extension housing.
6. REMOVE FRONT BEARING RETAINER AND BEARING SNAP RINGS




a. Remove the seven bolts and front bearing retainer.




b. Using a snap ring pliers, remove the two bearing snap rings.




7. SEPARATE INTERMEDIATE PLATE FROM TRANSMISSION CASE
a. Using a plastic hammer, carefully tap the transmission case.
b. Pull the transmission case from the intermediate plate.




8. MOUNT INTERMEDIATE PLATE IN VISE
a. Use two long clutch housing bolts, plate washers and suitable nuts as shown.

NOTE: Install the plate washers in reverse of normal. Increase or decrease plate washers so that the bolt tip and the front tip surface of the nut are aligned.

b. Mount the intermediate plate in a vise.
9. REMOVE LOCKING BALL AND SPRING




a. Using SST, remove the four plugs.
SST 09313-30021




b. Using a magnetic finger, remove the three springs and balls.
10. REMOVE SHIFT FORKS, SHIFT FORK SHAFTS AND REVERSE IDLER GEAR




a. Pry out the lock washer of No.1 shift fork and remove the set bolt.




b. Pry out the lock washer of No.2 shift fork and remove the set bolt.




c. Using two screwdriver and a hammer, tap out the snap ring of No.1 fork shaft.




d. Using two screwdriver and hammer, tap out the snap ring of No.2 fork shaft.




e. Remove the reverse idler gear shaft stopper.




f. Remove the reverse idler gear and shaft.




g. Remove the No.1 shift fork and shaft.




h. Using a magnetic finger, remove the No.1 and No.2 interlock pins.




i. Remove the No.2 shift fork and shaft.




j. Using a magnetic finger, remove the No.3 interlock pin.




k. Using a pin punch and hammer, drive out the No.3 fork shaft pin.




l. Pull out the No.4 shift fork shaft.




m. Remove the No.3 shift fork, fork shaft and reverse shift arm with the pin.




11. REMOVE SPEEDOMETER DRIVE GEAR
Pry out both ends of the clip and remove the drive gear.




12. INSPECT COUNTER FIFTH GEAR THRUST CLEARANCE
Using a feeler gauge, measure the counter 5th gear thrust clearance.

Standard clearance: 0.10 - 0.41 mm (0.0039 - 0.0161 in.)
Maximum clearance: 0.46 mm (0.0181 in.)

13. REMOVE COUNTER REAR BEARING, SPACER, COUNTER FIFTH GEAR AND NEEDLE ROLLER BEARING




a. Using a snap ring expander, remove the snap ring.




b. Using SST, remove the rear bearing, spacer, 5th gear and bearing.
SST 09213-36020

NOTE: Be careful not to catch the output shaft rear bearing roller on the counter 5th gear.

c. Remove the spacer.
14. REMOVE NO.3 HUB SLEEVE ASSEMBLY




a. Using two screwdrivers and a hammer, tap out the snap ring.




b. Using SST, remove the No.3 clutch hub.
SST 09950-20017

NOTE: Latch the claw of the SST onto the clutch hub not the shifting key retainer.

15. REMOVE OUTPUT SHAFT REAR BEARING AND FIFTH GEAR




a. Using two screwdrivers and a hammer, tap out the snap ring.




b. Using SST, remove the rear bearing and 5th gear.
SST 09312-20011
16. REMOVE REVERSE GEAR




a. Using a snap ring expander, remove the snap ring.




b. Using SST, remove the reverse gear.
SST 09950-20017
17. REMOVE CENTER BEARING RETAINER




a. Using a torx socket wrench, unscrew the torx screws and remove the retainer.
(Torx socket wrench T40 09042-00020)




b. Using a snap ring expander, remove the snap rings.




18. REMOVE OUTPUT SHAFT AND COUNTER GEAR AS A UNIT FROM INTERMEDIATE PLATE
a. Remove the output shaft, input shaft and counter gear as a unit from the intermediate plate by pulling on the counter gear and tapping on the intermediate plate with a plastic hammer.
b. Remove the input shaft from output shaft.




19. INSPECT BACK UP LIGHT SWITCH




Check that there is continuity between terminal as shown.
If operations not as specified, replace switch.