Transmission Installation

INSTALLATION
1. INSTALL GSA ASSEMBLY TO TRANSMISSION





a. Apply release hub grease to the release fork and clutch cable.
Sealant: Part No. 08887-01806, RELEASE HUB GREASE or equivalent
b. Pay attention to combine the clutch cable and clutch fork.





c. Pulling the clutch fork, install the GSA assembly.





d. Temporarily tighten the A and B bolts.

NOTICE:
^ Because the B bolt is tensed up by the release cylinder cable of the GSA assembly, hold the GSA assembly not to damage the bolt's thread when install the B bolt.
^ Install the B bolt before the A bolt.

e. Install the stiffener plate bracket with the 3 C bolts.
Torque: 42 Nm (428 kgf-cm, 31 ft. lbs.)
f. Tighten the A and B bolts.
Torque: 42 Nm (428 kgf-cm, 31 ft. lbs.)





g. Install the bolt.
Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)
h. Remove the actuator link fixing plate from the GSA assembly.





i. Install the GSA cover as shown in the illustration.
2. INSTALL REAR ENGINE MOUNTING BRACKET TO TRANSMISSION
3. INSTALL TRANSMISSION TO ENGINE
a. Using a transmission jack, lift up the transmission
b. Lower the engine left side.
c. Align the input shaft with the clutch disc, then slowly and carefully install the transmission to the engine.
d. Temporarily tighten the 4 mounting bolts of the transmission lower side.
4. INSTALL LEFT ENGINE MOUNTING BRACKET





a. Install the mounting bracket to the transmission with the 3 bolts.
Torque: 52 Nm (530 kgf-cm, 38 ft. lbs.)
b. Install the through bolt and nut.
Torque: 87 Nm (887 kgf-cm, 64 ft. lbs.)
5. REMOVE ENGINE SUPPORT FIXTURE





6. INSTALL 2 MOUNTING BOLTS OF TRANSMISSION UPPER SIDE
Torque: 64 Nm (650 kgf-cm, 47 ft. lbs.)





7. TIGHTEN 4 MOUNTING BOLTS OF TRANSMISSION LOWER SIDE
Torque:
47 Nm (480 kgf-cm, 35 ft. lbs.) for bolt A
23 Nm (230 kgf-cm, 17 ft. lbs.) for bolt B





8. INSTALL REAR ENGINE MOUNTING BRACKET
Install the mounting bracket with the 3 bolts.
Torque: 78 Nm (796 kgf-cm, 58 ft. lbs.)
9. INSTALL REAR ENGINE MOUNTING INSULATOR





a. Install the mounting insulator with the 4 bolts.
Torque: 89 Nm (908 kgf-cm, 66 ft. lbs.)
b. Install the through bolt and nut.
Torque: 93 Nm (949 kgf-cm, 69 ft. lbs.)

NOTICE: Be sure to tighten the bolt at the upper end of the slot.

10. INSTALL STARTER





a. Install the starter with the 2 bolts.
Torque: 37 Nm (378 kgf-cm, 28 ft. lbs.)
b. Connect the starter cable with the nut.
Torque: 9.8 Nm (100 kgf-cm, 87 inch lbs.)
c. Connect the starter connector.
11. INSTALL FRONT ENGINE MOUNTING BRACKET





a. Install the front engine mounting bracket to the transmission with the 2 bolts.
Torque: 78 Nm (796 kgf-cm, 56 ft. lbs.)
b. Install the through bolt and nut.
Torque: 93 Nm (949 kgf-cm, 69 ft. lbs.)
12. REMOVE TRANSMISSION JACK
13. INSTALL REAR DRIVE SHAFTS
14. REFILL TRANSMISSION OIL





15. CONNECT INPUT SENSOR CONNECTOR





16. INSTALL GSA CONNECTOR BRACKET
Install the connector bracket with the bolt.
Torque: 8 Nm (82 kgf-cm, 71 inch lbs.)
17. CONNECT GSA CONNECTORS
18. INSTALL THROTTLE BODY





19. CONNECT NEUTRAL START SWITCH CONNECTOR AND 2 BACK-UP LIGHT SWITCH CONNECTORS
20. CONNECT GROUND CABLE TO TRANSMISSION
Torque: 19 Nm (195 kgf-cm, 14 ft. lbs.)
21. CONNECT ENGINE WIRE TO TRANSMISSION





a. Connect the 2 clamps.
b. Install the engine wire with the bolt.
Torque: 8 Nm (82 kgf-cm, 71 inch lbs.)
22. CONNECT HPU CONNECTOR
23. INSTALL BATTERY BRACKET





a. Install the battery carrier with the 3 bolts.
Torque: 24 Nm (245 kgf-cm, 18 ft. lbs.)
b. Install the battery tray and also the battery with the battery clamp.
24. CONNECT SMT SYSTEM HOSES





a. Apply a light coat of sequential M/T fluid to the 3 new O-rings.
b. Install the 3 new O-rings.





c. Connect the 3 SMT system hoses by pushing downward until click sound is heard.
25. CHECK SMT SYSTEM FLUID LEVEL
26. INSTALL AIR CLEANER CAP AND AIR HOSE ASSEMBLY, AIR FILTER AND AIR CLEANER CASE
27. INSTALL SUSPENSION UPPER BRACE
Install the suspension upper brace with the 2 bolts and 2 nuts.
Torque:
74 Nm (755 kgf-cm, 55 ft. lbs.) for bolt
80 Nm (816 kgf-cm, 59 ft. lbs.) for nut
28. INSTALL ENGINE HOOD
a. Install the engine hood with the 4 bolts.
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
b. Adjust the hood.
29. PERFORM INITIAL LEARNING OF SET SYSTEM
30. CHECK FOR LEAK
31. CHECK AND INSPECT ITEM AS FOLLOWS
a. Check the rear wheel alignment.
b. Do the road test.