Disassembly of Transmission

1. REMOVE RELEASE FORK AND BEARING
2. REMOVE BACK-UP LIGHT SWITCH, SPEEDOMETER DRIVEN GEAR, SHIFT LEVER RETAINER, REAR SPEED SENSOR (w/ ABS) AND RESTRICT PINS
3. REMOVE CLUTCH HOUSING FROM TRANSMISSION CASE
4. REMOVE STRAIGHT SCREW PLUG, SPRING AND BALL




a. Using a torx socket wrench, remove the screw plug from the transfer adaptor.




b. Using a magnetic finger, remove the spring and ball.
5. REMOVE EXTENSION HOUSING




a. Remove the ten bolts.




b. Remove the shift lever housing set bolt.
c. Using a plastic hammer, tap the extension housing and remove the shift lever housing and shift and select lever.




6. REMOVE FRONT BEARING RETAINER
a. Remove the eight bolts.
b. Using a plastic hammer, tap the front bearing retainer.




7. REMOVE BEARING SNAP RINGS
Using a snap ring expander, remove the two snap rings.




8. SEPARATE INTERMEDIATE PLATE FROM TRANSMISSION CASE
a. Using a brass bar and hammer, carefully tap off the transmission case.
b. Remove the transmission case from the intermediate plate.




9. REMOVE MAGNET FROM INTERMEDIATE PLATE




10. MOUNT INTERMEDIATE PLATE IN VISE
a. Use two 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 front tip surface of the nut are aligned.

b. Mount the intermediate plate in a vise.
11. REMOVE STRAIGHT SCREW PLUGS, LOCKING BALLS AND SPRINGS




a. Using a torx socket wrench, remove the four plugs.




b. Using a magnetic finger, remove the four springs and balls.




12. REMOVE SHIFT FORK SET BOLTS




13. REMOVE SNAP RINGS
Using two screwdrivers and a hammer, remove the three snap rings.




14. REMOVE SLOTTED SPRING PINS
Using a pin punch and hammer, drive out the two pins.




15. REMOVE NO.5 SHIFT FORK SHAFT
Pull out the No.5 shift fork shaft from the intermediate plate.




16. REMOVE NO.2 SHIFT FORK SHAFT AND SHIFT FORK
a. Pull out the No.2 shift fork shaft from the intermediate plate.
b. Remove No.2 shift fork.
c. Using a magnetic finger, remove the interlock pin from the intermediate plate.




17. REMOVE NO.1 SHIFT FORK SHAFT
a. Pull out the No.1 shift fork shaft from the intermediate plate.
b. Using a magnetic finger, remove the interlock pins from the shaft hole and intermediate plate.




18. REMOVE NO.3 SHIFT FORK SHAFT AND NO.1 SHIFT FORK
a. Pull out the No.3 shift fork shaft from the intermediate plate.
b. Remove the No.1 shift fork.
c. Using a magnetic finger, remove the interlock pin and locking ball from the shaft hole and intermediate plate.




19. REMOVE NO.4 SHIFT FORK SHAFT, NO.3 SHIFT FORK AND REVERSE SHIFT HEAD
a. Pull out the No.4 shift fork shaft from the intermediate plate.
b. Remove the reverse shift head and locking ball.
c. Remove the No.3 shift fork.




20. REMOVE REVERSE SHIFT ARM FROM REVERSE SHIFT ARM BRACKET




21. REMOVE REVERSE SHIFT ARM BRACKET
Remove the two bolts and the reverse shift arm bracket.




22. REMOVE SPEEDOMETER DRIVE GEAR
a. Using two screwdrivers and a hammer, tap out the rear snap ring.
b. Remove the speedometer drive gear and ball.
c. Using two screwdrivers and a hammer, tap out the front snap ring.




23. REMOVE OUTPUT SHAFT REAR BEARING
a. Using two screwdrivers and a hammer, tap out the snap ring.
b. Using SST, remove the rear bearing.
SST 09950-20017




24. REMOVE SPACER




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

Standard clearance: 0.10 - 0.35 mm (0.0039 - 0.0138 in.)
Maximum clearance: 0.40 mm (0.0157 in.)

26. REMOVE NO.5 GEAR SPLINE PIECE, SYNCHRONIZE RING, NEEDLE ROLLER BEARING AND COUNTER FIFTH GEAR WITH NO.3 HUB SLEEVE




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




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




e. Using SST, remove the No.5 gear spline piece.
SST 09213-31021
f. Remove the counter 5th gear with No.3 hub sleeve.
27. REMOVE SHIFTING KEYS AND SPRINGS FROM 5TH GEAR AND NO.3 HUB SLEEVE
Using a screwdriver, remove the three shifting keys and two springs.




28. REMOVE THRUST WASHER AND BALL




29. REMOVE REAR BEARING RETAINER
Remove the four bolts and rear bearing retainer.




30. REMOVE REVERSE IDLER GEAR AND SHAFT
Pull out the shaft toward the rear.




31. REMOVE BEARING SNAP RING
Using a snap ring expander, remove the snap ring.




32. REMOVE OUTPUT SHAFT, COUNTER GEAR AND INPUT SHAFT AS A UNIT FROM INTERMEDIATE PLATE
a. Remove the output shaft, counter gear and input shaft 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 with the needle roller bearing from the output shaft.




33. REMOVE COUNTER REAR BEARING FROM INTERMEDIATE PLATE
Using SST and a hammer, remove the counter rear bearing.
SST 09608-12010 (09608-00020, 09608-00050)