Assemble

NOTE: The steel balls are all of the same size (5/16 inch).

1. Install the magnet and reverse lock cam.
2. Set shift arm A on the clutch housing, then install the shift rod.
3. Install the spring washer and shift arm A attaching bolt.
4. Install the steel ball, spring, and set ball spring bolt.
5. Install shift arm B in the interlock, then set it on the clutch housing.
6. Insert shift arm shaft in the clutch housing
7. Install the collar, spring, and steel ball into the case. Compress the ball and insert the shift arm shaft.
8. Install shift arm C in shift arm A, then insert the shift arm shaft.
9. Install the reverse select retainer and reverse select spring onto shift arm shaft.
10. Install the differential assembly.





11. Position the 36 mm spring washer and washer onto the mainshaft bearing.
12. Install the mainshaft, countershaft, and shift fork assemblies.

NOTE: Align the finger of the interlock with the groove in the shift fork shaft.





13. Install the spring washer and shift arm B attaching bolt
14. Install the 1st/2nd select spring, 28 mm plug bolt, and interlock guide bolt.

NOTE: Apply liquid gasket (P/N 08718 - 0001 or 08718 - 0003) to the threads of the 28 mm plug bolt and interlock guide bolt.





15. Install the reverse idler gear and reverse idler gear shaft.





16. Install the reverse shift holder.





17. install the oil gutter plate
18. Install the oil guide plate and thrust shim on the transmission housing.





19. Apply liquid gasket to the surface of the transmission housing mating with the clutch housing as shown.

NOTE:
- Use liquid gasket (P/N 08718 - 0001 or 08718 - 0003).
- Remove the dirty oil from the sealing surface.
- If 20 minutes have passed after applying liquid gasket, reapply it and assemble the housings.
- Allow it to cure at least 20 minutes after assembly before filling the transmission with oil.

20. Install the dowel pins and the transmission housing.





21. Lower the transmission housing with the snap ring pliers, and set the snap ring into the groove of the countershaft bearing.

NOTE: Check that the snap ring is securely seated in the groove of the countershaft bearing.

22. Install the 32 mm sealing bolt.

NOTE: Apply liquid gasket (P/N 08718 - 0001 or 08718 - 0003) to the threads.





23. Tighten the transmission housing attaching bolts in the numbered sequence in several steps shown below. 8 x 1.25 mm Torque to 27 Nm (20 ft. lbs.)





24. Install the steel balls, springs, and set screws.





25. Install the back-up light switch and transmission hanger.