M/T Assembly Reassembly

NOTE: Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact surfaces.

1.Install the magnet (A) and differential assembly (B).

 

2.Install the 36 mm spring washer (A) and 26 mm washer (B) over the ball bearing (C). Note the installation direction of the spring washer.

 

3.Apply tape on the mainshaft spline (D) to protect the seal. Install the mainshaft and countershaft (E) into the shift forks (F), and install them as an assembly.

4.Install the reverse idler gear (A) and the reverse gear shaft (B).

 

5.Install the reverse shift fork.

 

6.Select the proper size 52 x 62 mm shim (A) according to the measurements made during the mainshaft thrust clearance adjustment. Install the oil gutter plate (B), oil guide plate M, and 52 x 62 mm shim into the transmission housing (C).

 

7.Remove any dirt and oil from the tramsmission housing sealing surface. Apply liquid gasket (P/N 08718- 0002) to the sealing surface. Make sure you seal the entire circumference of the bolt holes to prevent oil leakage.

NOTE: Do not install components if too much time has passed after applying the liquid gasket (for P/N 08718- 0002, no more than 4 minutes, for all others, no more than 5 minutes). Instead, remove the old residue, and reapply the liquid gasket.

 

8.Install the 14 x 20 mm dowel pins (A).

 

 

9.Set the tapered conering (B) (5-speed model) as shown. Place the transmission housing over the clutch housing, being careful to line up the shafts.

10.Lower the transmission housing the rest of the way as you expand the 69 mm snap ring (C). Release the snap ring so it seats in the groove of the countershaft bearing.

11.Make sure the 69 mm snap ring is securely seated in the groove of the countershaft bearing.

Dimension (1) as installed: 3.3-6.5 mm
(0.13-0.25 in.)
 

12.Apply liquid gasket (P/N 08718-0002) to the threads of the 32 mm sealing cap (D), and install it on the transmission housing.

13.Install the 8 mm flange bolts, finger-tight.

 

14.Tighten the 8 mm flange bolts in a crisscross pattern in several steps.

8 x 1.25 mm 
27 N·m (2.8 kgf·m, 20 lbf·ft) 

 

15.Remove any dirt and oil from the change lever cover sealing surface. Apply liquid gasket ( P/N 08718- 0002) to the sealing surface.

NOTE: Do not install components if too much time has passed after applying the liquid gasket (for P/N 08718- 0002, no more than 4 minutes, for all others, no more than 5 minutes). Instead, remove the old residue, and reapply the liquid gasket.

 

16.Install the 8 x 14 mm dowel pins (A) and change lever assembly (B).

 

17.Install the drain plug (A), filler plug (B), speed sensor (C), and new O-ring (D).

 

18.Install the detent bolts (A), the springs, and the steel balls with new washers.

 

19.Install the 20 mm bolt (B) and new 20 mm washer (C).

20.Install the new washer (A), the back-up light switch (B), and the transmission hanger (C).

 

21.Install the air cleaner housing bracket (A) and the harness bracket (B).