Part 1

OVERHAUL





1. REMOVE CLUTCH RELEASE FORK SUB-ASSY
a. Remove the clutch release fork with clutch release bearing from the manual transaxle case.
2. REMOVE CLUTCH RELEASE BEARING ASSY
a. Remove the clutch release bearing assy and clutch release bearing hub clip from the clutch release fork sub-assy.





3. REMOVE RELEASE FORK SUPPORT
a. Remove the release fork support from the manual transaxle case.
4. REMOVE CLUTCH RELEASE FORK BOOT
a. Remove the clutch release fork boot from the manual transaxle case.
5. REMOVE SPEEDOMETER DRIVEN HOLE COVER SUB-ASSY
a. Remove the bolt and speedometer driven hole cover.





6. REMOVE SELECTING BELL CRANK ASSY
a. Remove the 2 bolts and selecting bell crank assy from manual transmission case.
7. REMOVE CONTROL SHIFT LEVER





a. Remove the nut and spring washer.





b. Using a brass bar and hammer, remove the shift outer lock pin.
c. Remove the control shift lever.





8. REMOVE CONTROL SHAFT COVER
a. Remove the 4 bolts and control shaft cover from the manual transmission case.





9. FIX MANUAL TRANSAXLE ASSY
a. Using wooden blocks, fix the manual transaxle assy.





10. REMOVE LOCK BALL ASSY NO.1
a. Remove the lock ball assy No.1 from the manual transmission case.





11. REMOVE MANUAL TRANSMISSION BREATHER PLUG
a. Remove the manual transmission breather plug and gasket.





12. REMOVE SHIFT & SELECT LEVER SHAFT ASSY
a. Remove the shift & select lever shaft assy from the manual transmission case.





13. REMOVE BACK UP LAMP SWITCH ASSY
a. Remove the back up lamp switch assy and gasket from the manual transmission case.





14. REMOVE MANUAL TRANSMISSION FILLER PLUG
a. Remove the manual transmission filler plug and gasket from the manual transmission case.





15. REMOVE DRAIN (MTM) PLUG SUB-ASSY
a. Remove the drain (MTM) plug sub-assy and gasket from the manual transmission case.





16. REMOVE MANUAL TRANSMISSION CASE COVER SUB-ASSY
a. Remove the 10 bolts and manual transmission case cover from the manual transmission case.
17. REMOVE MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT





a. Engage the gear to the double meshing.





b. Using SST and a hammer, loosen the staked part of the manual transmission output shaft rear set nut.
SST 09930-00010





c. Using SST, remove the manual transmission output shaft rear set nut from the output shaft.
SST 09229-55010
d. Disengage the double meshing of the gear.





18. INSPECT 5TH GEAR THRUST CLEARANCE
a. Using a dial indicator, inspect the 5th gear thrust clearance.
Standard clearance: 0.10 - 0.65 mm (0.0039 - 0.0256 inch)





19. INSPECT 5TH GEAR RADIAL CLEARANCE
a. Using a dial indicator, inspect the 5th gear radial clearance.
Standard clearance: 0.009 - 0.050 mm (0.0004 - 0.0020 inch)

HINT: If the clearance is out of the specification, replace 1st gear needle roller bearing.

20. REMOVE TRANSMISSION CLUTCH HUB NO.3





a. Using 2, screwdrivers and hammer, remove the transmission clutch hub No.3 shaft snap ring from the input shaft.

HINT: Using a waste to prevent the snap ring from being scattered.





b. Remove the gear shift fork bolt from the gear shift fork No.3.





c. Using SST, remove the transmission clutch hub No.3 and gear shift fork No.3 from the input shaft.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010), 09950-50013 (09957-04010), 09950-60010 (09951-00280)





21. REMOVE 5TH GEAR
a. Remove, the 5th gear from the input shaft.





22. REMOVE 5TH GEAR NEEDLE ROLLER BEARING
a. Remove the 5th gear needle roller bearing from the input Shaft.





23. REMOVE 5TH DRIVEN GEAR
a. Using SST, remove the 5th driven gear from the output shaft.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09957-04010), 09950-60010 (09951-00180, 09955-03011), 09950-50013





24. REMOVE BEARING RETAINER REAR (MTM)
a. Using a torx socket wrench (T45), remove the 7 torx screws and bearing retainer rear (MTM) from the manual transmission case.





25. REMOVE OUTPUT SHAFT REAR BEARING SHIM
a. Remove the output shaft rear bearing shim from the output shaft.





26. REMOVE INPUT SHAFT REAR BEARING SHAFT SNAP RING
a. Using a snap ring expander, remove the input shaft rear bearing shaft snap ring from the input shaft.
27. REMOVE SHIFT FORK SHAFT SNAP RING





a. Using 2 screwdrivers and a hammer, remove the shift fork shaft snap ring from the gear shift fork shaft No. 1.

HINT: Using a waste to prevent the snap ring from being scattered.





b. Using 2 screwdrivers and a hammer, remove the shift fork shaft snap ring from the gear shift fork shaft No.2.

HINT: Using a waste to prevent the snap ring from being scattered.





28. REMOVE REVERSE IDLER GEAR SHAFT BOLT
a. Remove the reverse idler gear shaft bolt and gasket.
29. REMOVE CLUTCH TUBE BRACKET NO.1
a. Remove the 3 bolts and remove the clutch tube bracket.
30. REMOVE MANUAL TRANSMISSION CASE





a. Remove the 3 bolts of the manual transaxle case side.





b. Remove the 14 bolts of the manual transmission case side.
c. Using a plastic hammer, remove the manual transmission case.





31. REMOVE OIL RECEIVER PIPE NO.2 (MTM)
a. Remove the bolt and oil receiver pipe No.2 (MTM) from the manual transmission case.

NOTICE: Do not damage the pipe.





32. REMOVE OIL RECEIVER PIPE NO.1 (MTM)
a. Remove the bolt and oil receiver pipe No.1 (MTM) from the manual transmission case.

NOTICE: Do not damage the pipe.

33. REMOVE REVERSE RESTRICT PIN ASSY





a. Using a hexagon wrench (6 mm), remove the reverse re strict pin plug from the manual transmission case.





b. Using a pin punch ([diameter]5 mm), remove the slotted pin and reverse restrict pin assy.





34. REMOVE TRANSMISSION MAGNET
a. Remove the transmission magnet from the manual transaxle case.
35. REMOVE REVERSE IDLER GEAR SUB-ASSY





a. Remove the reverse idler gear sub-assy from the manual transaxle case.





b. Remove the reverse gear and reverse idler thrust washer from the reverse idler gear shaft.





36. REMOVE REVERSE SHIFT ARM BRACKET ASSY
a. Remove the 2 bolts and reverse shift arm bracket from the manual transaxle case.
37. REMOVE GEAR SHIFT FORK SHAFT NO.1





a. Remove the shift fork bolt from the gear shift fork No.1.





b. Pull out the gear shift fork shaft No. 1 while the gear fork shaft No.3 is pulled up.





c. Using 2 screwdrivers and a hammer, remove the shift fork shaft snap ring from the gear shift fork shaft No.1.

NOTICE: Using a waste to prevent the snap ring from being scattered.





38. REMOVE REVERSE SHIFT FORK ROLLER
a. Using a magnetic finger, remove the reverse shift fork roller from the reverse shift fork.
39. REMOVE GEAR SHIFT FORK SHAFT NO.2





a. Remove the 2 shift fork bolts from the gear shift fork No.2 and gear shift head No.1.





b. Remove the gear shift fork shaft No.2 and gear shift head No.1 from the manual transaxle case.