Disassembly of Transmission

1. REMOVE RELEASE FORK. BEARING AND SPEEDOMETER DRIVEN GEAR
2. REMOVE BACK-UP LIGHT SWITCH
Using SST remove the back-up light switch.
SST 09817-16011




3. REMOVE TRANSMISSION CASE COVER




4. (C150)
MEASURE FIFTH GEAR THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance.

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




5. REMOVE LOCK BOLT




6. REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY




7. 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. (C140 and C141)
Remove the spacer.
e. Disengage the gear double meshing.




8. (C150)
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 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




9. (C150)
REMOVE FIFTH DRIVEN GEAR
Using SST and a socket wrench, remove the 5th driven gear.
SST 09213-36020




10. REMOVE REAR BEARING RETAINER




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




12. REMOVE REVERSE IDLER GEAR SHAFT LOCK BOLT




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




14. REMOVE PLUGS, SEATS, SPRINGS. BALLS AND LOCK BALL ASSEMBLY
a. (C150)
Using SST, remove the three plugs and lock ball assembly.
SST 09313-30021
(C140 and C141)
Using SST, remove the three plugs and straight screw plug.
SST 09313-30021
b. Using a magnetic finger, remove the three seats, springs and balls.




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




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




17. REMOVE REVERSE SHIFT ARM BRACKET
Remove the two bolts and pull off the bracket.




18. REMOVE SHIFT FORKS AND SHIFT FORK SHAFTS
a. (C150)
Using two screwdrivers and a hammer, tap out the three snap rings.
(C140 and C141)
Using two screwdrivers and a hammer, tap out the two snap rings.




b. Remove the three set bolts.




c. (C140 and C141)
Using a pin punch and hammer, drive out the slotted spring pin from the reverse shift fork.




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




e. (C150)
Using a magnetic finger, remove the two balls from the reverse shift fork.




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




19. REMOVE INPUT AND OUTPUT SHAFTS TOGETHER FROM TRANSAXLE CASE
20. REMOVE DIFFERENTIAL ASSEMBLY
21. REMOVE MAGNET AND OIL RECEIVER




22. MEASURE THIRD AND FOURTH GEAR THRUST CLEARANCE
Using a feeler gauge, measure the thrust clearance.

Standard clearance:
3rd gear 0.10 - 0.35 mm (0.0039 - 0.0138 in.)
4th gear 0.10 - 0.55 mm (0.0039 - 0.0217 in.)

Maximum clearance:
3rd gear 0.40 mm (0.0157 in.)
4th gear 0.60 mm (0.0236 in.)




23. REMOVE SNAP RING FROM INPUT SHAFT
Using two screwdrivers and a hammer, tap Out the snap ring.




24. REMOVE RADIAL BALL BEARING, FOURTH GEAR, NEEDLE ROLLER BEARINGS, SPACER AND SYNCHRONIZER RING FROM INPUT SHAFT
a. (C150)
Using SST, press Out the radial bail bearing.
SST 09950-00020
(C140 and C141)
Using SST and a socket wrench, press out the radial ball bearing.
SST 09950-00020
b. Remove the 4th gear, needle roller bearings, spacer and synchronizer ring.




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




26. REMOVE NO.2 HUB SLEEVE ASSEMBLY, THIRD GEAR, SYNCHRONIZER RING AND NEEDLE ROLLER BEARINGS
Using SST and a press, remove No.2 hub sleeve, 3rd gear, synchronizer ring and needle roller bearings.
SST 09950-00020




27. MEASURE FIRST AND SECOND GEAR THRUST CLEARANCE
Using a feeler gauge, measure the thrust clearance.

Standard clearance:
1st gear 0.10 - 0.40 mm (0.0039 - 0.0157 in.)
2nd gear 0.10 - 0.45 mm (0.0039 - 0.0177 in.)

Maximum clearance:
1st gear 0.45 mm (0.0177 in.)
2nd gear 0.50 mm (0.0197 in.)




28. REMOVE RADIAL BALL BEARING, FOURTH DRIVEN GEAR AND SPACER FROM OUTPUT SHAFT
a. Using SST and a press, remove the radial ball bearing and 4th driven gear.
SST 09950-00020
b. Remove the spacer.




29. REMOVE THIRD DRIVEN GEAR, SECOND GEAR, NEEDLE ROLLER BEARING AND SYNCHRONIZER RING
a. Shift No.1 hub sleeve into the 1st gear.




b. Using SST and a press, remove the 3rd driven gear and 2nd gear.
SST 09950-00020
c. Remove the needle roller bearing and synchronizer ring.




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




31. REMOVE NO. 1 HUB SLEEVE ASSEMBLY, FIRST GEAR, SYNCHRONIZER RING, NEEDLE ROLLER BEARING, THRUST WASHER AND LOCKING BALL
a. Using a press, remove No.1 hub sleeve, 1st gear and synchronizer ring.
b. Remove the needle roller bearing, thrust washer and locking ball.




32. DISASSEMBLE SHIFT AND SELECT LEVER SHAFT ASSEMBLY
a. Remove the E-ring, compression spring and seat.




b. Using a pin punch and hammer, drive out the slotted spring pins from No.1 and No.2 shift inner levers.
c. Remove No.2 shift inner lever.




d. Remove No.1 shift inner lever and the shift interlock plate.




e. Using a pin punch and hammer, drive out the slotted spring pin from the select inner lever.




f. Remove the select inner lever, compression spring and spring seat.




g. Using two screwdrivers and a hammer, tap out the snap ring from the lever shaft.




h. Remove the control shaft cover.