Assemble

Fig. 26 Checking Case Bolt Installation:

1. Install mainshaft/input shaft assembly in lower case. Apply suitable lubricant and ensure shaft assembly rotates smoothly.
2. Clean mating surfaces of upper and lower cases, then apply suitable silicone sealer on upper case mating surface and install upper case to lower case. Ensure all gears and forks are in neutral position.
3. Install case attaching bolts and ensure all bolts extend equally from the case, Fig. 26, then torque bolts to 17 ft. lbs.
4. Apply suitable silicone sealer to input shaft bearing retainer and suitable Loctite to retainer attaching bolts, then install retainer and attaching bolts. Torque attaching bolts to 17 ft. lbs.
5. Install clutch housing, then the attaching bolts. Torque attaching bolts to 37 ft. lbs.
6. Apply a small amount of suitable grease to release bearing, then install release bearing.
7. Clean transmission rear case mating surfaces, then apply suitable silicone to mating surface of rear case and install case to transmission assembly. Torque attaching bolts to 17 ft. lbs.
8. Install back-up lamp and 5th gear switches.
9. Install gear shift lever case.